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

info@intelligrated.com

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