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The reason more companies are turning to warehouse automation is because of the myriad of benefits that these automatic systems hold.
Warehouse robots are specifically designed to perform certain tasks with speed and precision. Humans can get tired and make unnecessary, costly mistakes.
Automating warehouse processes means repetitive tasks, like sorting or picking, can be done with high accuracy.
Not only do humans need breaks and time off, but working in dangerous or fast-paced environments can take a mental toll.
This is where robots come in. Robots can tackle stressful or hazardous jobs - for example, carrying heavy goods or lifting inventory to high shelves - taking the mental and physical strain off of human laborers.
By reducing this strain, workers tend to be more motivated and productive.
Oftentimes the tasks in warehouses are repetitive. Having people do these jobs manually can allow errors to occur as they tire or lose focus.
Robots can improve efficiency by performing these tedious tasks with the same level of precision each time. This allows people to focus on more complex tasks, like jobs that require fine motor skills or decision-making.
Robots can operate day and night without needing breaks. This means that the labor force can be smaller as fewer people are required to work different shifts. Although robotics may have large upfront costs, these systems save money in the long run.
Modern warehouses are forced to consider using robotics because of how competitive the industry has become. Robots are no longer just nice-to-haves; they've become indispensable parts of the supply chain management system.
Below are the most common types of Warehouse robots that are found in modern warehouse operations.
AVGs are used to transport inventory around a warehouse. These Autonomous Mobile robots replace forklifts or pick carts that are usually driven by humans.
AGVs generally move along pre-established routes marked by tracks or magnetic strips. Some have sensors and cameras to help them move around the factory floor, navigating obstacles and avoiding collisions.
AS/RS are computer-controlled systems that automate inventory management. They're able to move, store, and retrieve inventory on demand. This ensures high levels of inventory accuracy.
These automated systems can fetch or store products quickly. The entire system includes warehouse management software coupled with shuttles or cranes. These move on fixed tracks and can reach shelving to remove or store items.
The purpose of automated storage and retrieval systems is to increase the speed of material handling and the order fulfillment process.
Collaborative bots - also called Cobots - are Semi-autonomous Mobile robots that have been specifically designed to work alongside warehouse workers. These bots have a variety of uses in warehouses:
Cobots have computer vision systems and sensors that help them avoid collisions and navigate the floor without hassles.
Articulated robotic arms are pick-and-place bots with multi-jointed arms to manipulate and move products. A robotic arm can be used to turn, move, and lift products. Articulated robots are mostly fixed in place.
This technology functions on the same principles as AS/RS. It makes use of automated storage systems on the warehouse floor to deliver inventory to pick stations. Humans then complete orders at these stations.
Robotic technology is key to addressing a variety of challenges common in warehouse operations. Different robots play distinct roles, with the most advanced making use of artificial intelligence and machine learning to complete tasks.
Here are the most common functions of robots in warehouse automation:
This is the most common task performed by warehouse robots. Part of order fulfillment includes moving inventory along the aisles and bringing order items to human workers.
Picking robots transport products and can deposit them on shelves or in storage bins. These bots can reduce processing times and costs involved with order fulfillment.
Sorting can be repetitive and mundane for people. Robots involved with sorting have arms, sensors, cameras, and complicated algorithms to identify and sort items into the correct bins or areas.
Packaging robots and associated systems use cartonization and bagging machines to increase the speed of packing operations. They calculate the packaging size required for the products and seal, code, and label the packaging.
Automated guided vehicles are robots that can move around the warehouse floor to transport inventory. These robots either move on tracks or have sensors to allow them to avoid obstacles.
Robotic transportation does not only include robots moving around but also conveyor belts and rails that can transport goods.
Warehouse managers can use robots to automate replenishment systems. This means that the risk of stockpiles running low is reduced. These automated systems can automatically order new stock or send alerts when stockpiles run low.
AGVs can also be used to place new inventory in the storage areas.
With continuous technological breakthroughs and more and more people shopping online, robotics companies are constantly innovating and designing new robots.
Where robots usually only perform one specific function (except for articulated robotic arms with customizable end effectors), companies are now creating robots with multiple purposes.
That means that a warehouse can buy a single robot that can transport, pick, load, and pack products.
Cobots and G2P technology are also becoming more commonplace. They do not replace human workers, but instead assist them in their tasks, reducing the workload (and associated burnout).
Artificial intelligence and machine learning are still in their infancy, and the uptake of these emerging technologies means more advanced robots in the future.
Several factors must be considered before implementing robots into the warehouse system.
As discussed above, different types of Warehouse robots play various roles within the supply chain.
From ordering stock to fulfilling orders, Warehouse robots have their place. They can assist with inventory management, transporting products to reduce lead times, checking the quality of products, and packing and shipping boxes.
Robotics enable supply chains to scale up and continue to meet supply requirements, even as demand increases.
And it is not just within a single warehouse where Autonomous robots have benefits. Robotics can optimize supply chains at a global scale by automating logistics. They can be integrated with customs compliance processes to ensure goods are moved across borders without delays.
Despite the high initial investment in Warehouse robotics, these systems can perform a variety of tasks with precision and speed.
People get tired, injured, or make mistakes. By automating warehouse operations, the efficiency and productivity of the warehouse is improved. Robots can tackle dangerous tasks (like heavy lifting or getting products from high shelves), leaving people to tackle complicated tasks which further improves efficiency.
When robots are coupled with supply chain management solutions, a business can automate its processes completely. Inventory can be restocked without manually checking stock levels, products can quickly be moved across the floor, and orders are seamlessly fulfilled.
In the early years, robots were stationary. But thanks to modern technological advancements, they now have cameras and advanced sensors that allow them to navigate a workplace floor and work alongside people. This results in a safer, more productive, and more efficient warehouse.
There are a couple of challenges related to implementing Warehouse robotics. Below are the challenges and how they can be addressed:
It depends on the type of robot. Fully automating a basic warehouse can cost $1 million, with each bot costing around $20,000. Note that this is just an estimation.
The main disadvantages of warehouse robotics are:
Robots are indispensable to warehouse operations. They can perform tasks with precision and speed, and work alongside humans to improve the safety and efficiency of the warehouse.
As the use of robotics is becoming more commonplace, robotic companies will continue to deliver newer tech to simplify warehouse systems. Despite high initial costs, the benefits of robotic systems in warehouses are clear - these robots are here to stay.