Learning what is possible in warehouse robotics

Robot implementation insights

• A panel of experts from The Robotics Group of MHI, at ProMat 2023, discussed what’s possible now in warehouse robotics and automation integration.
• Robotic system integration, lessons learned and best practices were among topics discussed from members of The Robotics Group of MHI at ProMat 2023.

Robotic workforce training, implementation, system integration, safety and cost were among topics covered by The Robotics Group (TRG) panel of MHI at the “What’s possible now in warehouse robotics” session at ProMat 2023, March 20-23, in Chicago, organized by MHI.

Moderated by Chris Lingamfelter, TRG co-vice chair, panel members were:

• Jon Schechter, business development manager, AutoStore.

• Zuzana Kajuch, Zuka Consultancy (formerly Crate and Barrel).

• Corey Cook, senior program manager, Lockheed Martin.

• Bill Vining, co-founder Robot Advisory Group.

The Robotics Group (TRG) panel of MHI discussed “What’s possible now in warehouse robotics” session at ProMat 2023, March 20-23, in Chicago, organized by MHI and moderated by Chris Lingamfelter, TRG co-vice chair. Courtesy: Mark T. Hoske, CFE Media and Technology

Questions to the panelists from the moderator and audience follow, with panelists’ answers, edited for space and clarity.

What’s possible now in warehouse robotics?

Schechter: Half of ProMat 2023 show is robotics. Robotics aren’t only for the largest manufacturing or warehousing applications. Robotics can work for everyone in any sized application.

Kajuch: Robotics technologies are emerging in more applications for the third-party logistics (3PL) space.

Cook: Trends include artificial intelligence (AI), synaptic interfaces, robotics tied to industrial Internet of Things (IIoT) applications and holographics to know where appropriate assets are.

Vining: We see more interactive, integrated systems.

Are peoples’ perceptions changing about working with robots?

Vining: We see less fear that robots are going to take jobs and more understanding that robots can be applied to make jobs safter and more fulfilling.

Cook: Perceptions are changing, and it helps to get people involved in robot implementation. Use of collaborative robotics (cobots) in operations are increasingly eliminating workforce insecurity. Workers often name the robots and affix license plates to them.

Kajuch: People are understanding that robots are fun, easy to use and interactive. It’s unbelievable how fast training can be. Naming the robots seems universal. People use the robots to quickly create a higher productivity baseline and appreciate the help collaborative robots provide. People not working well with robots tend to quickly stand out with lower productivity compared to coworkers who are enjoying the work.

Schechter: People appreciate that it’s safer and easier working with robots than in the past. Collaborative robots have more intuitive operations.

The Robotics Group (TRG) panel of MHI discussed “What’s possible now in warehouse robotics” at ProMat 2023, March 20-23, in Chicago, organized by MHI. Panelists, left to right, were Jon Schechter, business development manager, AutoStore; Zuzana Kajuch, Zuka Consultancy (formerly Crate and Barrel); Corey Cook, senior program manager Lockheed Martin; and Bill Vining co-founder Robot Advisory Group. Courtesy: Mark T. Hoske, CFE Media and Technology

Are use of drones becoming more accepted?

Vining: Autonomous self-flying drones, flying robots, have collision avoidance and would not be used in warehousing or other application if unsafe.

What are some robotic system integration best practices?

Vining: Every implementation is custom and shouldn’t be. We should be working on standards to make robot system integration more scalable and remove effort. This also would make robotic integration easier for information technology (IT).

What are some success factors for robot installations?

Kajuch: Certainly, operational productivity helps define success. Kiva claims 475 items picked per hour; I never saw that before. [Editor note: Human workers typically can pick 50 to 100 items per hour, depending on the application.] Existing employees may not do not do well in a collaborative robotic or robotic-guided picking environment and may need to be applied elsewhere. Gamers showing high levels of hand-eye coordination often work best in robotic picking applications.

Cook: In military applications, we may need to be able to support 600 million parts, and be able to identify and correctly route a single unpackaged bolt with certain material properties. With automation inventory accuracy improved from 66.9% to 99.8% in just three months. In the project, target return on investment (ROI) of 12 months was achieved in nine months.

What are some lessons learned with robotics?

Schechter: It takes organizational change and involvement to implement robotics effectively. It doesn’t work if only one person is excited about robotics. Involve those in charge of safety, information technology (IT), users and software and programming in robotics planning and system integration.

Cook: Integration with maintenance data systems is important. Knowing workflows when integrating with automation is important. Also consider wireless networks, cybersecurity, cyber-resiliency and where components are manufactured.

Kajuch: If documentation hasn’t been updated to current usage in a plant or facility, more site work may be needed for mobile robot implementation, such as walking the floor to make layout adjustments. (In the case cited, simulation software was not used, she noted later.)

Schechter: By fitting more into every tote, one customer realized about 40% truck savings, for an intralogistics and network-wide transformation.

Kajuch: While one project was justified on ecommerce, a second part of the project improved picking for replenishing stores. The pick list was shockingly diverse in count, and automation helped.

Cook: Conditions were hot and sweaty, and a facility was losing workers. They stabilized the work cycle by adding automation. Cycles leveled out. Even some workers who left returned. The site was able to allocate workers to other areas. A site that desperately needed workers increased worker satisfaction and retention with automation.

Vining: A grocery project using a cobot and automation helped with an older workforce as many were retiring. Labor is changing. Automation can perform require work faster and more safely.

Kajuch: Robotics can be an amazing technology for demanding workplaces with a high injury rates. Some jobs are too demanding for a human body to do for many years. Automation increases the level of job satisfaction.

Schechter: Many in the newly hired workforce are technology centered and expect to use robotics. Soon every job will have collaborative technologies to help people do their jobs better. In cold-chain applications, robotics can be adapted more readily than rotating people out of the cooler to warm up and help avoid injuries.

How can automation be more accessible to 80% to 90% of US warehouses without automation?

Vining: Robotics and other automation can be expensive. Return on investment (ROI) is important. Start small with a pilot. Start by looking at an automated example of something that looks like your site. Maybe try robotics with a year commitment to start.

Do you have advice to perfect robotic use with automation?

Schechter: Examine people and processes first. Then apply automation. Re-engineering a manual process is easier with everyone on board.

Vining: Work on the process first. In many cases, the process may not be optimal. Do not automate a bad process. Rework the process first.

What do you do to calm safety skeptics who fear robots?

Lingamfelter: Crate & Barrel said robots would break wine glasses. I filled the glasses with wine and drove them around. The robots didn’t break the glasses or spill the wine. The customer bought a system.

Cook: There’s a story of people jumping in front of mobile robots to prove their safety. Doing so is not recommended, but it worked in at least one case.

Lingamfelter: We thank all the early adopters for helping to encourage others with automation and robotic system integration.

Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

KEYWORDS: Mobile robots for manufacturing, warehouses, distribution centers

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