robotics Archives

MODEX 2016: What’s Hot…What’s Not

Material Handling | By Clint Reiser • 04/06/2016

I sit tonight, Tuesday, April 5th, writing about MODEX from a public hotel computer. I will fully disclose that I am using a public computer because I spilled coffee on my laptop earlier today. I feel as if I have been accepted into the fraternity of office fools…

For those of you unfamiliar with MODEX, it is the sister show to Promat, also hosted by MHI, and similarly focused on material handing and warehouse automation. A full range of material handling, warehouse automation, and other supply chain technologies are exhibited each year. However, I have noticed that each year’s show has its own common thread or theme that jumps out due to its prevalence. Last year at Promat I noted that the exhibitors were heavily focused on ecommerce fulfillment, adding additional emphasis on the differentiation and value offered by their software applications. Similar to Promat last year, this year’s MODEX show is heavily focused on ecommerce fulfillment. However, this year the prevalent themes that jumped out at me are the increased emphasis on shuttle systems and autonomous mobile robotics and the software development efforts and advancements in real-time processing and optimization.

Shuttle systems are not new. Autonomous robotics in the warehouse are new, but not within the past year. However, the evolution of both technologies is striking. Most (all?) major warehouse automation suppliers now offer a shuttle system with some vendors such as SSI Schaefer and KNAPP offering multiple shuttles that target a range of requirements. Futhermore, the systems are becoming more flexible, allowing users to adapt to changing order profiles and throughput requirements – both essential capabilities for ecommerce fulfillment. At the same time, autonomous mobile robotics has moved from the concept phase to commercial availabilty and practical consideration. Meanwhile, the advancements in software capabilities have been focused on providing and leveraging real-time information. To be clear, I am not referring to mechatronics. Rather, the advancements leverage real-time information to enable dynamic business process adjustments in the warehouse.

Below are brief overviews of notable and novel shuttle systems and autonomous robotics systems on display at MODEX 2016.

Movers and Shakers

SSI Schaefer CUBY
SSI offers a range of multi-level shuttle systems, but recently added its CUBY single level shuttle to the mix. CUBY is a fast moving shuttle for bins and/or cartons that is scalable and suitable for ecommerce and other variable, high volume warehouse environments.

KNAPP YLOG
Knapp, like SSI, offers a number of shuttle systems. However, it recently added the YLOG shuttle to its suite of shuttles. The YLOG shuttle, logically enough, came to Knapp through the acquisition of YLOG. The newest version is an enhancement of the model obtained at time of acquisition. This shuttle is a 3D system, in the sense that it runs on single level similar to single level shuttles, but can also pivot 90 degrees and run on the perpendicular axis. Finally, the shuttle can be moved to different levels while maintaining its power capabilities.

Intelligrated OLS
Intelligrated recently joined the list of vendors with a market-ready shuttle system. Its OLS (one-level shuttle) can carry a wide payload range and is able to roam from level to level for additional flexibility. Intelligrated currently has two active OLS customers with the first expected to go-live next quarter (Q3).

Fetch Robotics Freight
I have previously mentioned the robotics start-up, Fetch Robotics, on LogisticsViewpoints. Fetch Robotics was demonstrating its Freight robot in the Follow-pick mode application in which the robot works with associates by following them through the picking process and then autonomously dispatches the order to its warehouse destination while the picker continues with his/her picking process.

Locus Robotics
Locus Robotics demonstrated its order fulfillment system that features its LocusBots. Its robots work with warehouse staff to increase worker and overall warehouse productivity. The value driver of this solution appears to be its flexibility and the intelligence with which it utilizes the robots and staff to efficiently manage the facility workload.

Omron/Adept Lynx
Omron recently acquired Adept and with it obtained its robotics solution sent. Lynx is an autonomous robot that has fairly widespread deployment in light manufacturing operations, primarily wafer fabrication clean room facilities. Although the solution has its roots in light payload manufacturing environments, clearly Adept has established its robotics capabilities and is in a good position to leverage its expertise toward warehouse applications either through direct go-to-market or in partnership with warehouse automation systems integrators.

Autonomous Mobile Robotics in the Warehouse TODAY?

Logistics Technologies | By Clint Reiser • 01/06/2016

Last year, ARC Advisory Group published its first formalized research study on the global warehouse automation & control market. The publication was well-received by market participants. Due to the high level of demand, ARC has decided to update the study this year. I came into the office on January 4^th with this market study update in mind, thinking to myself “what will I find to be the areas of greatest change over the last year?”

E-Commerce Isn’t Slowing Down
The ongoing, rapid growth of e-commerce continues to place exceptional burdens on existing fulfillment networks. Not surprisingly, warehouse technologies that support high volumes of small, multi-line orders are receiving the greatest interest from practitioners as they realign their capabilities with the changing demand profile. In the warehouse automation market, this can be seen in the growing adoption of goods-to-person automation, namely in the form of shuttle systems that offer high levels of performance and flexibility. In addition, demand for even greater flexibility, and the exit of Kiva Systems from the market, is stimulating some exciting product development and early adoption of autonomous mobile robotics (AMR) for the warehouse. These emerging robotics systems are being developed by a number of start-up firms and established warehouse automation providers. Although robotics have physical characteristics, the embedded intelligence and application software are the key differentiating characteristics of these systems. Here is brief overview of the landscape for AMR in the warehouse, as I currently see it (in no particular order)

AMR – Coming soon to a Warehouse near You

Knapp Open Shuttle
The Open Shuttle is an AMR marketed along with Knapp’s existing line of carton and tote handling shuttles that includes the YLOG-shuttle and the OSR Shuttle. The Open shuttles utilize trackless navigation but also directly integrates with complementary systems such as the OSR shuttle. Open shuttles are generally available and in use at client sites, as evidenced by a new release stating Grene in Denmark obtained the Knapp Open shuttle in 2012 and uses it in conjunction with the OSR Shuttle.

Locus Robotics System
Locus Robotics, a Massachusetts based start-up, developed and deployed a new multi-robot fulfillment system at the facility of its development partner, Quiet Logistics. The robots and warehouse associates work together in a manner designed to reduce travel time and increase productivity by utilizing a novel work process. Associates scan items and place into totes transported by the robots. The robots autonomously navigate through the warehouse infrastructure along with others in the fleet, guided by the Locus server.

Swisslog CarryPick
Swisslog CarryPick AGVs retrieve mobile racks and deliver to manned workstations. A fleet of CarryPick AGVs execute tasks simultaneously and are controlled by Swisslog’s warehouse management system. The system uses QR codes placed on the floor to provide the he AGVs with the required orientation capabilities. Although Swisslog refers to the vehicles as AGVs, they do appear to function autonomously with trackless navigation. CarryPick AGVs are generally available and DB Schenker in Sweden is referenced customer currently using the system.

GreyOrange Butler
GreyOrange, a fast growing start-up based in India, has developed an automated goods-to-person system featuring its Butler robots. The Butlers navigate the warehouse floor, retrieving mobile racks and delivering the racks to pick stations for efficient manual picking of orders from the shelves. The system also conducts ABC analysis to rearrange mobile racks with fast moving goods to the most convenient locations. The robots utilize trackless navigation guided by QR codes placed on the floor. The Butler system is generally available and currently in use at a couple client sites.

Fetch Robotics Freight (and Fetch)
Fetch Robotics, a Silicon Valley start-up, has developed a robot “team” consisting of a mobile base called Freight and a mobile picking arm called Fetch. Freight can be used with Fetch or in support of a warehouse associate. In the latter application, the Freight robot can follow associates to order picking locations and once order items are picked and placed in tote on Freight, the Freight robot can be dispatched to shipping while another autonomous Freight robot then arrives to support the warehouse associate to support the next order pick. Last I heard, Fetch Robotics has moved beyond the academic phase and was in the process of testing in a commercial setting.

Scallog System
The Scallog System is a goods-to-man automated solution that leverages an autonomous robotics fleet that transports mobile shelving to picking stations. I only recently became aware of this French company, and therefore have limited knowledge of its currently operating status. However, a press release on the company’s website states that the IDEA Logistics Group is testing the Scallog System.

Hitachi Racrew
Finally, Hitachi has developed an automous mobile warehouse robotics system branded Racrew. Information in English is currently limited, but a video presentation is available for viewing on the internet.

ARC’s Supply Chain Predictions for 2015: Hits and Misses

Logistics Trends | By Steve Banker • 12/07/2015

At the beginning of the year the ARC supply chain team made supply chain predictions for 2015. This article circles back and reports on how we did.

Very often any predictions you can make for a one year period are not about a brand new thing that will occur, the prediction is really part of a larger megatrend that has not only been going on for some time but will also continue for many years to come.

The megatrends affecting supply chain management include:

The goal of the article was to produce forecasts specific enough so that their validity could actually be checked at the end of the year. We made some specific predictions surrounding these megatrends.

Robotics

The big player in this space was KIVA, which was acquired by Amazon and then stopped supporting the bots they had already sold.

We predicted that that in 2015 we will see new types of mobile robots for the warehouse emerge from other suppliers.

Hit: Grey Orange, a India-based robotics manufacturing company, is producing warehouse robots that look much like Kiva bots. Fetch Robotics has produced a system with two robots that work together. Fetch is a bot with a single arm that ends in a two-fingered gripper that can pick boxes off warehouse shelves and pass them to its sidekick, Freight. Both bots have a wheeled base. Once the order has been assembled, Freight can carry the goods to a shipping station while Freight continues to pick to the next Freight bot that has just arrived. There are other suppliers we have not mentioned here, and still others we know of that are poised to enter the market.

The Industrial Internet of Things

We’ve made the argument before that the Internet of Things (IoT) is nothing new in logistics. In the logistics space, for example, we’ve been taking RF scans and using that data to improve warehouse processes since at least 1975. But IoT is getting a lot of attention, and new investors in this space should mean new solutions.

We predicted we will continue to hear of new IIoT applications emerging, ways to use remote sensor data to improve supply chain business processes, that never occurred to us.

Hit: One interesting example we heard of how IoT and modeling can be combined comes from last year’s Long Beach labor strikes. As shippers shifted volume to other ports they found other shippers were doing the same. Delays by port were changing on a day by day basis. What if models of port throughput were used and combined with AIS Vessel tracking data (a form of sensor data)? If the model understood how many ships were sitting outside a port, how many were headed to that port, the relative sizes of those ships, and the throughput capacity of the port, shippers could have made much better port scheduling decisions.

Big Data

IoT sensors are going to generate Big Data. Big data volumes are going to continue to grow exponentially. Solutions are needed to handle not just the growing volume of data, but also the velocity and variety of data. Complex event processing (CEP) technologies can help to tame data velocity. CEP technologies have been traditionally associated with financial trading.

We predicted that this is the year we will hear of good applications for CEP in the supply chain.

Hit: Actually, we stole this prediction from our colleague David White, who is ARC’s expert on analytics. We circled back to David and asked if he had seen good applications for CEP in the supply chain. He pointed us toward an article called Shipping logistics with event processing.

Omni-channel

Omni-channel investments by retailers have been all over the news. ARC’s research shows that distributed order management (DOM) is one of two key technologies that retailers need, but don’t have, to ramp up their omni-channel capabilities. But DOM is a complex solution, it can’t be easy to implement. In all our years as analysts, the ARC supply chain team has heard only one speech by a retailer on how their omni-channel implementation improved their multi-channel capabilities, and this speech talked about the implementation at a very high level.

We predicted that in 2015 I would finally see a good presentation by a retailer that goes into depth on the costs, benefits, and difficulties associated with a DOM implementation.

Miss: We still have not seen that presentation.

Relentless Competition

The most brutal competition is currently occurring in the shale oil patch where the cost of a barrel of oil plummeted. And yet, from a supply chain perspective, this is among the worst supply chains in North America. Further, shale oil producer’s key partners, the oilfield service companies, also run terrible supply chains. In neither industry are you likely to find practitioners talking about their Sales & Operations Planning processes.

We predict that we will finally see Shale Oil companies and Oilfield Services companies explaining to Wall Street how they are implementing a Sales & Operations Planning to improve operations.

Miss: A Google search fails to find any evidence that this is true. However, the need for S&OP in Shale Oil is being talked about much more by leading consultants than it was a year ago.

The ARC supply chain team will be back with a new set of logistics and supply chain predictions for 2016 in a few weeks.

Robotic Mobility with Human Assist: Transforming E-Commerce Fulfillment

Logistics Outsourcing | By Chris Cunnane • 02/19/2014

Last week, I attended my first ARC Industry Forum in Orlando, FL. There were a lot of fascinating sessions that examined 3D printing, cyber security, the Internet of Things (IoT), predictive analytics, and a host of challenges and changing conditions in the discreet and process manufacturing industries. However, the session that stood out most to me was an early afternoon session on Tuesday Feb 11: Robotic Mobility and Human Assist Push the Outer Limits of Manufacturing.

This session did not speak to me so much from a pure manufacturing standpoint. Instead, the presentation by Bruce Welty, CEO of Quiet Logistics, looked at how robots are helping to transform e-commerce fulfillment. A few weeks ago, I wrote a column titled The Truth about the Omni-Channel Customer Experience. The article discussed how there were significant technology and customer empowerment gaps that are derailing the customer experience. At the heart of the customer experience is order fulfillment. If customers are unable to get the product they want, when they want it, they will simply go someplace else. Quiet Logistics is helping e-commerce retailers ensure they can fulfill orders accurately and on-time to improve the customer experience.

To give you some background, Quiet Logistics uses proprietary technology and Kiva Systems material handling robots in warehouses to drive order fulfillment accuracy and speed. The key to this system is not to use robots to replace workers. Instead, according to Welty “robots are enhancing humans, not replacing them. We use the robots to do the things humans are bad at.” So what does this mean for order fulfillment?

There has been a lot of talk about moving towards more automated processes to reduce labor costs. And for some aspects (OK, lots) of the business makes sense. As Sandy Vasser, Facilities Electrical and Instrumentation Manager, ExxonMobile indicated in his keynote, “You can’t do it wrong if you don’t have to do it.” This speaks loudly to the virtues of automation. But not everything can be automated. The Robotic Mobility track looked at this from both sides: robots replacing humans and automating processes as well as robots and humans acting as complementary pieces of the puzzle. Order fulfillment is one of these areas that cannot be fully automated.

Welty stated that “Fulfillment is crucial for e-commerce.” In the changing retail landscape, there are myriad shopping options for customers, and expectations have grown. E-commerce sales are up and continuing to grow. Many retailers are downsizing physical store footprints to expand e-commerce operations. But at the end of the day, if the order cannot be fulfilled on-time and accurately, it is a moot point. The consumer will go elsewhere that can fulfill the order. So how does Quiet Logistics provide fulfillment services for retailers?

The Kiva Systems robots do not bring individual items to be packed. Instead, these robots quickly bring the entire shelf to their human counterparts. This allows the human to pick the items that are needed for an order. If there are multiple items that need to be picked, and they are in separate shelves or bins, another robot can retrieve the next shelf while the human is picking the first part of an order. This combination allows the human to make sure they are picking the right components (in case the products are not in the right order on the shelf) while eliminating wasted time and movement of searching the warehouse floor.

From a fulfillment standpoint, Quiet Logistics’ services include inbound processing, inventory control, outbound processing, and returns processing. E-commerce fulfillment customers include Bonobos, Zara, Gilt Groupe, and Topps. Kiva Systems LLC is a wholly owned subsidiary of Amazon.com.

For more information on the presentation, please look for ARC Advisory Group’s post Forum review.

Supply Chain 2050

Consumer Packaged Goods (CPG) | By Steve Banker • 04/08/2013

An interesting and useful exercise for logistics executives to do at their annual strategic planning meeting is to ask, What are the megatrends that will change the face of logistics in five years? Ten years? Twenty years? And even forty years?

For me, the three biggest megatrends are robotics in logistics (both for the warehouse as well as driverless cars/trucks, and maybe even drones), omni-channel fulfillment, and the need to develop new distribution models to address the bottom of the economic pyramid.

We have written a fair bit about the first two trends, but not so much about the third trend – “consumers” at the bottom of the economic pyramid. Florian Güldner at ARC wrote a strategic report called “The Structure of Manufacturing in 2050” (available to ARC clients only) that provides some good coverage of the third megatrend. Here’s an excerpt:

“Economists typically use a pyramid to represent the global distribution of wealth. The ‘bottom of the pyramid’ refers to the four billion poorest people in the world, in particular the segment of around 1.5 billion people living on from $2.50 to $7.50 per day. While much attention has been paid to the growing middle class in emerging economies, business with the lowest income class has been neglected for a long time.”

Many Western multinational firms understand that growth will largely come from developing countries. Procter & Gamble, for example, has a goal to acquire 1 billion new customers. This goal is not reachable by just focusing on an emerging middle class. Unilever seeks to sell Lifebuoy soap by educating 1 billion poor Asians and Africans about the health benefits of handwashing.

The logistics challenges include the need to deliver goods packaged in small handling units to a large number of extremely small footprint store fronts; making deliveries in both crowded, congestion-choked metropolises as well as remote villages; and terrible infrastructure. The size of the goods delivered can range from very small – “Danone sells a small, 50-gram pouch of drinkable yogurt in Senegal that doesn’t require refrigeration for roughly 10 cents” — to low cost bulk goods like bags of rice.

Local sourcing can also help consumer goods companies be perceived as good corporate citizens while improving the buying power of small farmers. But the farm-to-fork supply chain is blemished by very high spoilage.

And when you deal with small, unsophisticated retail outlets, engaging in a robust forecasting process is difficult, although this problem is not insurmountable (see “How a Large CPG Company Runs an Efficient Supply Chain in Developing Countries”).

The cool chain, transporting temperature-sensitive food products, is obviously more challenging. Further, the need for developing a cool chain for the developing world is increasing because of new innovations allowing storefronts to carry more of these products. “A craftsman in Gujarat, India created a $40 terracotta refrigerator using the natural cooling of clay to work without electricity. It can store water, fruits, and vegetables for eight days and milk for one day.”

For large multinationals, this is the last untapped market that can help to drive robust growth. The easy route would be to hand the job over to distributors. But distributors often won’t have an interest in supplying the goods of just one manufacturer. For large multinationals, the challenge is to accept the job of distributing to very small retailers, or alternatively, to use their supply chain expertise as an additional value add that will make the distributors view the manufacturer as a preferred partner.

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