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The Robots Are ComingHow Robotic Solutions, Used for Decades in Manufacturing Plants, Are Moving Downstream Into Today’s DCs
The Robots Are Coming | www.intelligrated.com
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The Robots Are Coming: Robotic Materials Handling
Applications in Distribution and Fulfillment Centers
Robots, Automation and the Drive Toward a Smarter Supply Chain
What’s Aroung the Corner?
When It Comes to Automation Solutions,
Consider Robots a Part of Your Plan
The Robots Are Coming | www.intelligrated.com 1
The Robots Are Coming: Robotic Material Handling Applications in Distribution and Fulfillment CentersHow Robotic Solutions, Used for Decades in Manufacturing Plants, Are Moving Downstream Into Today’s DCs
For decades, robots have been a common sight
in manufacturing plants across the globe. From
upstream production and assembly applications,
welding, fabrication and painting to downstream
end-of-line tasks such as case packing and
palletizing, robots are tried and true productivity
solutions in manufacturing. The applications that
they perform share a common thread of precision
and repeatability – the sweet spot of historical
robotic applications. Any process which calls for the
same task to be completed repeatedly, particularly if
it is dirty, dull or dangerous, is a prime candidate for a
robotic application.
However, as the capability of robotic mobility, vision
guidance and control software evolves, so does
the ability of robots to function in more dynamic
and unstructured environments – functions
that are more closely aligned with tasks that
are done manually in today’s distribution and
fulfillment centers. This new frontier will call for
robotic solutions that are capable of performing
unpredictable, inexact, not always repeatable tasks,
and require a higher degree of spatial and object
awareness through use of real-time, adaptive
control algorithms. This paper will compare
traditional material handling solutions with their
robotic counterparts within the distribution and
order fulfillment center, and where these solutions
might be heading in the future.
Robots, Automation and the Drive Toward a Smarter Supply ChainThe high costs and multiple employee touches
associated with product receiving, shipping and
order filling in today’s distribution and fulfillment
centers provide potential targets for robotic
automation. These functions include: receiving;
put away and replenishment; order fulfillment;
pack out; and shipping. Let’s take a closer look at
how some of these operations have traditionally
been handled and then review potential robotic
solutions that could assist workflow.
What’s Around the Corner?Given the increasing velocity of innovation
and investment in robotics, we can expect that
both cost and complexity of existing robotic
solutions will diminish. Scientists and engineers
are working on developing low-cost, high-
functionality robots, equipped with high degree
of freedom (DOF) arms and highly adaptable
grippers. Coupling this with cameras, sensors
and sophisticated software will enable robots
to “see” objects, “feel” forces and “understand”
tasks. There is a desire to develop robots that
replace continuous repetitive tasks and are able
to safely interact with individuals to assist them in
performing specific tasks done manually today.
The Robots Are Coming | www.intelligrated.com 2
FIGURE 1 - Robotic Solutions in Distribution and Fulfillment
OPERATION MANUAL SOLUTION ROBOTIC SOLUTIONAPPLICATION EVOLUTION*
Receiving
Floor load truck unloading Automatic robotic truck unloading
Sort, segregate and label Integrated sort and label by robot (build pallets or cross-dock)
or
Single or multi-SKU robotic palletizing
Put-Away and Replenishment
Pallet transportation Intelligent mobile robotics
Pallet and case rack and shelving Random case storage and retrieval
De-casing to tote Robotic vendor case preparation
Fulfillment
Stand and pick from pallet Robotic depalletizing
or
Goods to robotic pick station
Ride and pick to pallet Mobile robotic case pick
Walk and pick to belt Robotic case pick isle
Push and pick to cart Robotic pick from vendor case
Walk and pick to tote Robotic pick from vendor case
Packing
Order consolidation Robotic operator
Carton forming Machine automation
Manual product insert Machine/robotic automation
Dunnage Machine/robotic automation
Packing slip and promotional inserts Machine/robotic automation
Manual close Machine/robotic automation
Manual label Machine/robotic automation
Shipping
Manual floor truck loading Robotic mix case floor loading
Manual pallet building Robotic pallet building
Manual full pallet delivery Robotic pallet trailer load
*Based on today’s technology, capabilities and expected ROI, the more filled in the circle, the closer the solution is to widespread adoption.
The Robots Are Coming | www.intelligrated.com 3
When It Comes to Automation Solutions, Consider Robots a Part of Your PlanIncreasing productivity while controlling cost
will continue to drive more workflow automation
into the supply chain. While not every aspect of
the distribution center activity is a candidate
for robotic automation, new improvements in
robotic technologies will help DC operators
understand and create more efficient workflow
areas to remain competitive and maximize
profitability. Our best advice is to discuss
potential robotic applications with a certified
robotic material handling integrator partner,
and discern how and when the best time is to
consider deployment of robotic solutions.
For more
information,
contact Honeywell
Intelligrated®
by email at
info@intelligrated.
com, by phone at
866.936.7300,
or visit www.
intelligrated.com.
Honeywell Intelligrated +1 866.936.7300
www.intelligrated.com
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