Warehouse Robotics – The Ultimate Guide for 2024

Your Guide to Warehouse Robotics in 2024

Robotic automation is transforming warehouse operations. Lifting, moving, sorting and picking by machines with varying amounts of built-in intelligence is allowing warehouse operations and distribution centres to increase their productivity, accuracy, and safety. Automated systems are being used to manage complicated processes, high risk tasks or simply repetitive actions. This automation is allowing businesses to cut labour costs, streamline operations and boost their efficiency.

This guide explores the types of warehouse robotics available and the benefits of using advanced robots in your warehouse. It also highlights challenges that can arise when you implement and use robots in your warehouse, and how to overcome these.

How Warehouse Robotics Help Businesses

Human-operated machines have been a feature of warehouse operations for a long time. Robots are machines that can carry out operations once performed by people, and do it automatically. Today’s robots are just dumb devices doing the same thing over and over. They communicate, often wirelessly, with the warehouse management system. They use sensors to guide their actions, allowing them to make decisions.

Increasingly, the systems that guide them make use of machine learning and artificial intelligence so they can become even more efficient. As your warehouse management system gathers more information about day-to-day operations, you can make better-informed choices about how it should be designed and run.

Using robots allows you to make better use of your human team. It frees your labour force from repetitive, manual activities such as moving stock from place to place, and allows them to perform activities that add more value.

Robotic automation can also reduce the volume of errors and levels of stock damage and loss. Warehouse robots, once programmed to perform a task, will do it over and over without getting tired and making mistakes. They don’t get bored, lose concentration or become distracted.

Automation brings health and safety benefits. Reducing the risk of human error and automating tasks such as lifting and moving heavy items makes the working environment safer. There’s less risk of accidents and injuries to human workers when robots are doing more of the work.

Increased productivity through efficiency, less damage and loss of stock and a safer working environment are all benefits that can result from increased automation of a warehouse and distribution centre. Of course, getting the best results comes from careful planning and implementation of the automated systems.

The good news is that costs of robotic technology and artificial intelligence systems are allowing these tools to become available to smaller businesses. Access to warehouse robotics is no longer limited to the biggest companies with the biggest budgets. Small and mid-sized firms are now able to take advantage of robotic process automation.

Types of Warehouse Robotics

There are an increasing number of warehouse robots in use today, ranging from compact autonomous mobile robots to large scale automated storage and retrieval systems. The potential use and benefit of each type of warehouse robotics should be thoroughly assessed to understand the best fit for your warehouse automation requirements, as each environment will differ according to their leverage, use cases, and the challenges that they solve.

There’s a wide range of specialised warehouse robotics available to the SME market today, including:

Automated Guided Vehicles (AGVs)

AGVs are used in operations to replace manually driven forklifts or pick carts. Automatic AGVs can be programmed to follow established routes around the warehouse facility that are marked by sensors, wires, and magnetic strips. Modern AGVs utilise cameras, Lidars, and infrared to navigate the warehouse, providing a safe way to move goods to and from the desired locations

Autonomous Mobile Robots (AMRs)

AMRs are similar to AGVs but they don’t need fixed tracks to navigate between two locations. AMRs are highly versatile and come equipped with specialised software with on-board advanced sensors used for navigation around the warehouse. Using SLAM (Simultaneous Localisation and Mapping) technology AMRs also have the intelligence to avoid any obstacles they might come across by assessing the warehouse environment and navigating its own way round it.

Automated Storage and Retrieval Systems (AS/RS)

These are a group of computer-controlled systems that help automate inventory management facilitating on-demand automated storage and retrieval of the inventory. AS/RS systems use shuttles and tracks that can easily traverse often narrow inventory aisles which not only enhance storage capacity but also speed up the order fulfilment process. As the structures are fully automated, they can be designed with narrow spaces between aisles and take advantage of the full height of the building. This compact storage solution is therefore able to use a much smaller footprint than other types of storage equipment such as pallet racking.

Collaborative Robots (Cobots)

Cobots are semi-autonomous mobile robots designed to assist warehouse employees in picking tasks. These mobile robots essentially follow workers around the warehouse floor as they pick various orders, with the collaborative robots acting as a mobile storage trolley. Cobots help to speed up pick efficiency and also remove potential strain on the worker with having to lift or carry items to the pick stations.

Articulated Robotic Arms

Robotic Arms are multi-jointed limbs that are capable of many different types of warehouse activities. Their flexible robotic arms are used to move, turn, lift and manoeuver items and are ideally suited to picking, packing, storing and palletising the inventory within a warehouse setting.

Goods-to-person (G2P) Robots

Working on a similar principle to AS/RS, goods-to-person robots are used to remove the required inventory from an automated storage system and deliver it to stationary pick stations where human operators fulfil orders. This level of automation enhances warehouse operations through accuracy and efficiency, eliminating the potential for manual picking errors.

Benefits of Warehouse Robotics

Warehouse robotics has the potential to make a significant difference to warehouse operations including inventory management, pick efficiency and overall warehouse safety and enable businesses to stay competitive in today’s dynamic logistics marketplace.

Improved Accuracy

Robots can also help to improve the accuracy of warehouse operations by eliminating errors caused by human error. People make mistakes when they are tired, distracted or don’t have the information needed to make the right decisions. This can lead to stock levels becoming inaccurate or the wrong quantities being picked and packed.

Robots can be programmed to perform actions that they repeat over and over, until told to do otherwise. They will scan barcodes and RFID tags, locate and pick items from shelves or bins, and track inventory levels with a high degree of accuracy. This helps to reduce errors and improve inventory accuracy, which can have a positive impact on customer satisfaction and business performance.

Improved Efficiency

Robotics can help to streamline operations, reduce manual labour, and increase productivity. Using robots it’s possible to run a 24/7 operation. The machines don’t require breaks or rest, and will perform repetitive tasks without becoming bored. They’ll perform consistently with high precision and speed, making it easier to plan.

Your human team works alongside the automated systems, bringing the adaptability and decision-making that’s beyond the scope of the robots. This working together makes best use of the strengths of your human and robotics teams, making warehouse operations more efficient and reducing the time and cost required to complete tasks.

Enhanced Safety

Robotics can help to improve safety in the warehouse by reducing the risk of accidents and injuries caused by manual handling or heavy lifting. Robots can lift and move heavy items without requiring human intervention, reducing the risk of injuries caused by lifting and carrying heavy loads. This can help to create a safer working environment for employees and reduce the risk of workplace accidents.

Scalability

Robotics can be easily scaled up or down depending on the needs of the warehouse. Additional robots can be added as required to handle peak periods or seasonal fluctuations in demand, while robots can be deactivated or removed during quieter periods to reduce costs. This can help to improve flexibility and agility in the warehouse, enabling businesses to respond quickly to changes in demand.

Cost Savings

There are several areas where your investment in warehouse robotics can help you save costs over time.

Staff costs: As you automate tasks, your need for human labour reduces. Another staff cost saving is that you may be able to reduce staff turnover. Because your team is engaged in work that adds value, and are doing less of the repetitive moving and lifting, they should find their work more rewarding. When you have the right leadership in place, this can help reduce the risk of staff leaving.

Energy costs: Automation will require energy to function. However, this can be offset by savings elsewhere. Automated systems can function in low light conditions, giving considerable opportunities for savings across large warehouses.

Reduced loss and waste: Because automated systems are less prone to errors than humans, you should see a reduction in the amount of stock being damaged as it’s moved around the warehouse. Because you have more accurate inventory records, there’s a reduced risk of stock being overlooked and becoming spoiled or obsolete. Using a smaller human workforce also reduces the risk of loss due to theft.

Supply Chain Management

Robotics play a vital role in warehouse automation and continue to address common challenges in supply chain management, including:

• More complicated fulfilment strategies
• Changing order profiles
• Rising employment costs and wages
• Decreased labour availability in the market

In particular, robotics can be used to enhance the following warehouse operations:

Picking

Picking is the most common warehouse operation performed by warehouse robots. As picking operations account for more than 55% of a warehouse or distribution centre costs, the integration of robotics technology to enhance pick activity could provide a timely solution, not only to reduce order processing times and risk of order picking errors, but also the associated costs by reducing travel time through the warehouse.

Sorting

Warehouse robots used for sorting tasks will typically have additional components such as conveyors, arms, cameras and sensors, as well as the intelligent integrated software used to interact with the warehouse management system which allows them to accurately identify the inventory item and allocate it to the correct tote or storage area.

Packaging

Warehouse robotics include automated systems such as cartonization software and bagging machines that help speed up packaging operations. These systems work with features such as products’ overall weight and dimensions to calculate the ideal carton size for orders and direct associates to the correct task.

Transportation

Carrying items from one end of the warehouse to another is physically demanding and decreases the amount of time a worker can spend doing value-added tasks in the fulfillment process. Robotic transportation systems such as conveyor systems and AGVs help to transport pallets and goods from one location to another, thus reducing human footprint, and associated stress or fatigue.

Replenishment

Some warehouse robots can automate replenishment workflows, thus reducing risk of low stock and backorders through automated re-ordering. Such automated warehouse systems can monitor inventory levels and send out alerts when inventory counts drop below the minimum threshold. Other automations like AGVs can direct workers in the replenishment process when new inventory arrives, keeping order processing on track and efficient.

Challenges of Integrating Warehouse Robotics

While there are clear and significant benefits to integrating warehouse robotics into warehouse operations, there are also challenges that come with potentially implementing any form of new technology.

High Initial Investment

The initial investment required to purchase and install robotics in a warehouse can be significant. The process of analysing your needs, designing an automation solution and installing it can require a considerable amount of capital. The cost of installing robotics has been a barrier to smaller businesses, or those with limited budgets. You need to be confident that the expected return on your investment is in line with your business strategy.

Technical Complexity

Robotics systems can be complex, requiring specialised technical knowledge and skills to install and maintain. This means that businesses may need to invest in training or hire additional staff to manage the robotics system, which can be challenging for some organisations.

Integration with Existing Systems

Integrating robotics with existing warehouse management systems and processes can be challenging. The robotics system must be able to communicate with other systems, such as inventory management and order processing, to ensure that warehouse operations are optimised. This can require significant technical expertise and may take time to implement.

Operational Disruption

Introducing new technology into a warehouse environment can disrupt operations and require changes to existing processes. This can cause a temporary decline in productivity as employees adjust to the new system and learn how to work with the robots. Disruption can be reduced by paying attention to details, such as ensuring the user interface, the point of contact between human and machines, is easy to understand.

Maintenance and Repair

Robotics systems require regular maintenance to ensure that they operate efficiently and effectively. This may require specialised technical knowledge and skills, which requires intervention from third-party suppliers. Procedures for planning and monitoring will help machine downtime to be minimised.

Workforce Resistance

Introducing robotics into a warehouse environment can lead to workforce resistance, particularly if employees feel that their jobs are threatened. Businesses must communicate the benefits of the robotics system to their employees and provide training to ensure that workers are comfortable with the new technology.

Summary

Automated systems have become increasingly popular in warehouses and distribution centres, with robots now playing a more significant role in the distribution of goods. Warehouse robotics has the potential to add significant value to warehouse operations, delivering enhanced inventory management, pick efficiency and improving overall warehouse safety.

Robots are highly versatile and adaptable, assisting with eliminating costly manual errors, speeding up order fulfilment and facilitating better inventory and supply chain management. Furthermore, with the ongoing labour shortage affecting the UK warehouse and logistics sector, warehouse robotics provide a reliable, accurate alternative to warehouse staff, capable of carrying out important tasks such as order processing and replenishment, often faster and more efficiently than when performed by your human team.

The health and safety benefits of robotics can’t be overlooked. The costs of hiring, training and retaining labour are a significant overhead, pushing up the costs of a warehouse operation. These expenses are also more controllable when being spent on robotics, as it’s easier to anticipate and plan for their servicing and maintenance.

Introducing and integrating warehouse robotics can pose challenges. However, with careful assessment of needs, implementation planning and management, these challenges can be overcome, and the significant benefits of warehouse robotics can be realised.