Robotics 101: A Complete Guide to Warehouse Robots by Application

It was the year 1946 when the term ‘automation’ was first used by D.S. Harder, an engineering manager at Ford. Ever since, the term has been widely used in the manufacturing industry. Generally, automation is defined as a technology that can operate by means of programmed command and without human intervention. As you can probably guess, one of the most well-known automation technologies we see today is robotics.

It does not come as a surprise that the robotics industry is booming. In fact, the global robotics market is projected to reach €175.8B by 2025, growing at a 26% Compound Annual Growth Rate (CAGR). Evidently, robots already play an undeniable role in many industries and will continue to do so as technology advances. 

Deciding which types of robots to deploy in your facility is definitely not an easy task. We hope this overview will help you understand the available technologies and make your decision-making process a little bit easier.

A Brief Introduction to AGVs and AMRs

Automated Guided Vehicles (AGVs)

Source: Bastian Solutions

Automated guided vehicles (AGVs) have been around for decades. One of the main characteristics of AGVs is that they do not require an onboard operator or human driver. They are material handling systems or load carriers that are used to transport stock and other materials around warehouses following fixed routes. 

Sensors, magnetic stripes or wires embedded in the warehouse’s concrete floors, barcodes on storage racks, or wireless beacons on walls allow AGVs to carry goods from one point to another, following a predetermined path. Moreover, recent technologies have enhanced the ability of AGVs to detect obstacles and avoid collisions by using LiDAR (light detection and ranging) sensors and computer-vision cameras.

AGV Navigation

Rail Navigation

As the name suggests, rail-guided navigation allows warehouse robots to travel through the facility by following rails connected to predefined routes.

Magnetic Tape Navigation

Very much like rail navigation, magnetic tape-based navigation is a navigation system based on physical guidance where robots follow predefined paths. These paths are created by magnetic tape so that the robot can easily follow the desired route.

Wire-guided Navigation

Wire-guided navigation is also similar to the previously mentioned physical guidance navigation systems. However, instead of following a rail or magnetic tape, it follows a wire. The main difference between these systems is that the wire is located underneath the warehouse floor rather than being attached to it. These robots operate based on a system that uses an electromagnetic field. This field is created by a current which flows through the wires in the floor. This solution is very beneficial for those who do not want the navigation path to interfere with other traffic such as forklifts.

Label-based Navigation

With label-based navigation, robots use data from a 3D laser range finder to classify objects such as doors, floors, and shelves. The robot’s ability to recognise these objects is what determines its position in the environment. Tasks can be assigned to the robot through a map of the environment which contains semantic labels. For example, the label “navigate to the closest door” will direct the robot to the desired location. This system is used for localisation and object recognition purposes.

Laser-based Navigation

Laser-based navigation is a system used in many forms — label-based navigation being one of them. When using a laser-based navigation system, the robots will rely on lasers entirely when mapping the environment three-dimensionally. It is very common for such a system to be connected to algorithms in embedded microcontrollers or processors.

Vision-based Navigation

Vision-based navigation systems use laser sensors, too, to a certain degree. In order to visually interpret the environment, vision-based navigation makes use of optical sensors — such as photometric cameras with CCD arrays or laser-based range finders. The data collected by these sensors is used to avoid obstacles in the environment as well as for the positioning of the robot.

LiDAR

LiDAR stands for Light Detection and Ranging and its sensors are used by robots to navigate throughout their environment. LiDAR sensors transmit information based on a series of laser pulses. This lets the system measure the distance between the robot and other objects in the environment. By compiling all of this data, LiDAR is able to create a comprehensive, 360-degree map of the facility. This allows robots to flexibly navigate throughout the warehouse without causing collisions and other accidents. Moreover, when paired with machine learning and AI, LiDAR can ensure that robots will choose the most efficient navigation route.

Common Applications of AGVs

AGVs are often used for the transportation of raw materials — such as plastic, metal, steel, paper, and rubber — and can thereby ensure that production lines are always provided with the materials they need. In fact, the AGV can pick up the material when it arrives at the warehouse and deliver it directly to the production lines without interrupting the production process.

Autonomous Mobile Robots (AMRs)

Source: SICK Sensor Intelligence

Unlike AGVs — which travel via fixed, predetermined routes guided by tracks and the like — AMRs are guided by built-in maps and an array of sophisticated sensors. These enable them to interpret and understand their environment and navigate through facilities autonomously. Thanks to these built-in sensors and maps, AMRs have the ability to identify the information of goods and other objects and are able to sort packages precisely. 

Besides offering high levels of efficiency, consistency, accuracy, and security during the sorting process, AMRs are able to create their own routes, reroute when necessary, and avoid any kinds of obstacles in their way — including human workers. This makes them a flexible and safe alternative to AGVs. They are also specifically designed to collaborate with picking and sorting operations, to name a few, whereas most AGVs do not.

AMR Navigation

Label-based Navigation

With label-based navigation, robots use data from a 3D laser range finder to classify objects such as doors, floors, and shelves. The robot’s ability to recognise these objects is what determines its position in the environment. Tasks can be assigned to the robot through a map of the environment which contains semantic labels. For example, the label “navigate to the closest door” will direct the robot to the desired location. This system is used for localisation and object recognition purposes.

Laser-based Navigation

Laser-based navigation is a system used in many forms — label-based navigation being one of them. When using a laser-based navigation system, the robots will rely on lasers entirely when mapping the environment three-dimensionally. It is very common for such a system to be connected to algorithms in embedded microcontrollers or processors.

Vision-based Navigation

Vision-based navigation systems use laser sensors, too, to a certain degree. In order to visually interpret the environment, vision-based navigation makes use of optical sensors — such as photometric cameras with CCD arrays or laser-based range finders. The data collected by these sensors is used to avoid obstacles in the environment as well as for the positioning of the robot.

Geo-guidance

Geo-guidance navigation systems use sensors, connected to a reference map, to help robots recognise their surroundings and establish their position in the warehouse. The map lets robots determine their route by identifying certain objects such as pallets, rack, and walls.

LiDAR

LiDAR stands for Light Detection and Ranging and its sensors are used by robots to navigate throughout their environment. LiDAR sensors transmit information based on a series of laser pulses. This lets the system measure the distance between the robot and other objects in the environment. By compiling all of this data, LiDAR is able to create a comprehensive, 360-degree map of the facility. This allows robots to flexibly navigate throughout the warehouse without causing collisions and other accidents. Moreover, when paired with machine learning and AI, LiDAR can ensure that robots will choose the most efficient navigation route.

Common Applications of AMRs

Repetitive tasks that humans would spend their valuable time on — such as transporting a cart from A to B — can easily be automated with mobile robots. For example, AMRs can help transport goods during the production process in the form of shelf units. This way, the workers who fill the shelves with goods can simply summon the robot and send it on its way again with just one simple click. In the same way, an AMR can also be designed with a conveyor top module so that it can transport goods from one fixed conveyor belt to another.

Another common application of AMRs in logistics is in the form of an automated pallet fork, where they are used to tow pallets. The AMR will be able to locate the pallet fork and autonomously transport it to its desired destination in the most efficient manner. This, too, takes away a lot of valuable time from the workers as they simply have to load and unload the pallet without having to transport it across the facility.

Types of Warehouse Robots by Application

We can see a wide variety of AGVs and AMRs roaming the warehouses. This, however, also leads to a number of major challenges when it comes to communication between different robots: each manufacturer supplies its robots with its own operating system. With the growing demand and diversification of mobile robots, the need for interoperability becomes more and more important. However, thanks to the advances in recent technologies, warehouse robots are improving their functional capabilities and are becoming much better at navigating through their environments. This provides a positive outlook on the future communication capabilities of mobile robots. 

Understanding how difficult it must be to find the perfect robot for your facility, we have listed down the most common applications and types of warehouse robots based on their most common use type. However, keep in mind that some of them can be used for more than one type of application. If you are specifically looking for a software solution for the management of your robot fleet, we have answered the most common questions in our FAQ section. 

“Please note that the prices and specifications are no guarantee as they are merely based on averages and estimations. All of these factors will depend on your project, facility, which supplier you choose, and so forth. The product images are collected from various suppliers and their only purpose is to help you visualise the different types of robots. We do not receive any type of compensation for promoting the suppliers, nor do we have any commercial obligations towards them.”

— Editor's Note

1. Warehouse Robots that Transport Products and Freight

Forklifts and pallet trucks have been carrying out loading and unloading tasks for many years. However, warehouses are speeding up these processes by adopting automated guided vehicles (AGVs) such as automated forklifts. Even though there are some robots that can perform tasks like removing pallets from trailers and placing them on conveyor belts for further transportation, there still is a long way to go before warehouses can fully realise automated loading and unloading.

AGVs are commonly used for the repetitive movement of materials during the production process. This also makes them a very popular choice when it comes to pallet handling in manufacturing and distribution centres. They can also carry dangerous materials — think of radioactive substances and chemicals. This allows companies to remove human workers from harmful, hazardous environments, thereby optimising operational safety.

Automated Forklifts

As mentioned before, forklift AGVs are one of the most common types of AGVs. They are specifically designed to perform the exact same tasks — such as transporting pallets — that were traditionally carried out by a human-operated forklift, only without needing a human to operate them.

The following automated forklift types are most commonly used in warehouses. Note that the image below is a collection of automated forklift models from ASTI Mobile Robotics and is no exact representation of the following forklift types.

Source: ASTI Mobile Robotics

• Automated Pallet Jack: Also referred to as pallet movers, Automated Pallet Jacks are the smallest type of autonomous forklift and are modelled after the traditional pallet jack. It offers limited vertical load movement and works mainly on a horizontal level — reaching pallets on racks and shelves close to the floor as well as floor-to-floor operations. 

• Counterbalanced Automated Guided Forklifts: This type of forklift locates the weight of the carrying load in the truck’s rear and is ideal for moving pallets to and from the storage areas. They are most often deployed in shipping and receiving operations.

• Straddle Forklift AGVs: The straddle forklift AGV — or: outrigger AGV — has two horizontal legs which stabilise the forklift and do not need as much space to manoeuvre. This type also requires less space than the counterbalanced automated guided forklift. 

• Very Narrow Aisle Width AGVs (VNAs): VNAs are specifically designed to carry heavier loads and are a great fit for warehouses that utilise high vertical storage space and consist of many narrow aisles. 

However, with new technologies on the rise, we can now also see forklifts that are highly intelligent and can operate autonomously. This means that, rather than following a fixed, predetermined route the way AGVs do, the automated forklift navigates through its environment using advanced features such as laser technology, scanners, sensors, 3D cameras, and so forth.

Automated Forklifts
Types	Max Speed	Load Height	Load Capacity	Min. Aisle Width	Price Indication
Automated Pallet Jack	2 m/s	1.5 m	1.5K kg	3.6 m	€37K - €62K
Counterbalanced Automated Guided Fork Truck	2 m/s	9 m	2.5K kg	4.5 m	€70K - €100K
Straddle Forklift AGV	2 m/s	4 m	1.5K kg	3.7 m	€66K - €100K
Very Narrow Aisle AGV	2 m/s	11 m	1.2K kg	1.6 m	€125K - €166K

Just as with any other type of AMR, autonomous forklifts can detect and move around obstacles and are highly capable of collaborating with other operators — making them suitable for both small and larger fleets. Their built-in logistics solution enables them to know the exact location of goods and what would be the optimal route to get there. Most automated forklifts can even calculate the loading process time and assign tasks to themselves. As they are not fully able to carry out all tasks just yet, they are commonly used together with manually operated forklifts. 

Suppliers:

ASTI Mobile Robotics

Swisslog

Agilox Systems

Vecna Robotics

On the other hand, there are also AMRs that can help a warehouse to eliminate forklifts from the work floor completely. Heavy-duty AMRs — such as the MiR500 pallet lift — can take over tasks like pallet lifting, transporting, towing, and delivering. Their ability to navigate through the facility autonomously makes AMRs a safe alternative to manually operated forklifts.

Pros and Cons

Based on the information above, we can highlight the following advantages and disadvantages of automated forklifts:

Pros	Cons
1. Reduction of Labour Requirements	1. Heavy Initial Investment
Automated forklifts can handle many jobs at the same time and can take over heavy, dangerous, and repetitive tasks.	While automated forklifts may reduce costs long-term, the investment is a bit high from a short-term perspective.
2. Safety Improvements	2. Limited Flexibility
By reducing human involvement, injury rates will decrease.	They are often programmed to take on repetitive tasks only.
3. Increased Efficiency	3. Lack of Interoperability
Automated forklifts help achieve goals in much less time, which enhances productivity.	Automated forklifts from different suppliers are not able to communicate with each other.

Towing AGVs

Towing AGVs — also referred to as tugger automatic guided vehicles or towing vehicles — are able to pull load-carrying vehicles that are non-motorised behind them, just like the locomotive of a train carrying numerous wagons. Towing AGVs are often used to transport heavier goods via pre-defined, long-distance routes and may stop several times along the way at drop-off and pick-up points.

Towing AGVs are generally classified by their load capacity and come with either magnetic or optical navigation, or laser or LiDAR sensor navigation. Even though some towing AGVs are capable of carrying extremely heavy loads, 85% of all towing AGVs can carry up to 2 ton. There are even some towing AGVs that can tow up to 20 ton, however, these are mostly used for outdoor applications. Also, note that some towing AGVs are not based on manual standard tow tractors, which means they cannot be operated manually. 

Source: Vecna Robotics

Towing AGVs
Types	Max Speed	Magnetic or Optical Navigation	Laser or LiDAR Navigation
Towing AGV up to 1K kg	60m/min	€17K	€25K
Towing AGV up to 3K kg	60m/min	€23K	€29K
Manual Towing AGV up to 3K kg	240m/min	37K	45K

Suppliers:

Aethon

AutoGuide Mobile Robots

Dematic

Vecna Robotics

Thanks to new technologies, we can now also see a more autonomous variant to the towing AGV, such as the automated pallet fork from MiR. This robot will be able to locate a pallet fork within its environment and transport it to the desired destination autonomously.

Pros and Cons

Based on the information above, we can highlight the following advantages and disadvantages of towing AGVs:

Pros	Cons
1. Easy to Install and Adopt	1. Manual Operation
As they serve as a substitute for manned tow tractors, towing AGVs are easy to deploy.	Even though some of them can operate autonomously, they will still need to be hooked manually.
2. High Transportation Capacity	2. Risky Compared to Other AGVs
Towing AGVs are able to transport several unit loads with different types of products in one go.	As the towing AGV train contains several trolleys, there is a lack of a common safety system and interoperability.
3. Fast Speed
They are speedy vechiles.

Unit Load AGVs and Heavy Burden Carriers

As the name suggests, unit load AGVs move unit loads between fixed conveyors. They are known to carry individual loads such as single objects or units. An example of this could be a pallet or container which holds multiple smaller items. Unit load AGVs are commonly used in manufacturing and warehouse distribution, where they optimise their production and assembly line operations.

As illustrated below, two different types of unit load AGVs can be distinguished: the conveyor deck (left) and the lift deck (right). Whereas the latter is ideal for carrying heavy loads that cannot be transported with forklifts, the conveyor deck is commonly used for the handling of smaller loads between fixed conveyors.

Source: Scott Systems

Again, technological advancements have led to new possibilities for conveyor systems. AMRs allow for the attachment of conveyor top modules, which can work as an autonomous link between fixed conveyors. With the AMRs ability to easily change routes and positions, this offers a flexible, agile, and fully automated solution to the — typically time-consuming — logistic process of moving conveyors around.

On the right-hand side, an example of the type of AGV most commonly used for carrying the heaviest loads is illustrated — the heavy burden carrier. Their great load capacities make a great choice for picking and towing heavier materials. Most of them can also be used to transport workers. They are designed to clear narrow aisles and their agility allows them to navigate through tight spaces with ease.

Suppliers:

MiR (Mobile Industrial Robots)

Transbotics, Scott Systems

Dematic

Source: Scott Systems

Pros and Cons

Unfortunately, we have not been able to find specific information regarding price ranges. Note that there are many different types of unit load AGVs and heavy burden carriers, especially since suppliers often offer customisable models based on specific operational requirements. 

However, based on the information above, we can highlight the following advantages and disadvantages of unit load AGVs and heavy burden carriers:

Pros	Cons
1. Flexible Assembly Lines	1. Size
These AGVs improve flexibility in terms of layout, scalability, and assembly line relocation.	Depending on the model, both of these AGVs can take up a significant amount of space.
2. Capacity to Carry Heavy Loads	2. Limited Flexibility
Some of them can carry loads up to 20 ton and perhaps even more when customised.	Unit load AGVs and heavy burden carriers are typically programmed to take on repetitive tasks only.
3. System Failure Does Not Affect Operations	3. Lack of Interoperability
If these AGVs experience system failure or downtime, the assembly lines will keep moving.	Unit load AGVs and heavy burden carriers from different suppliers are not able to communicate with each other.
4. Agility
Unit load AGVs and heavy burden carriers move through their environment at ease and can operate in tight spaces.

2. Warehouse Robots That Assist with Picking, Packing, Sorting, and Storing

Easy as it may seem, sorting is a pretty complex process to automate. During the sorting process, the warehouse robots that are specifically designed for sorting processes must be able to pick up objects, identify them, and then place them in the correct spot. With their accuracy, high efficiency, and ability to reduce order processing times, it is no surprise that picking robots accounted for the largest share of the warehouse robotics market in 2016. 

Besides reducing order fulfilment costs, many picking robots these days are able to navigate through a facility autonomously and are thereby reducing walking time. Along with the fact that 65% of a warehouse's operational costs are spent on labour, it is easy to understand why warehouses are so eager to automate their picking operations. In fact, more than 70% of warehouses and fulfilment centres have been seeing double-digit improvements in their operations ever since they deployed AMRs.

As we have seen earlier, AMRs are able to eliminate a lot of unnecessary walking across the warehouse. Thanks to advancements in sensors, mobility, and artificial intelligence, AMRs are easy to deploy in any kind of warehouse setting. A common application of AMRs is transporting goods from one place to another, also known as a goods-to-person system. This can be between different workers, picking and sorting areas, production and packaging stations, and so forth. Their main purpose for deployment remains to eliminate walking: a human worker would typically spend half of the picking task on walking.

Automated Storage and Retrieval Systems (AS/RS)

Automated Storage and Retrieval Systems (AS/RS) include a variety of warehouse robots such as mini-load systems, cranes, and pallet shuttles. AS/RS solutions typically follow a predetermined track and are connected to a warehouse management system (WMS) which directs the operations. They are specifically designed to operate in tight spaces and are ideal for narrow aisles and great heights. Not only does their ability to store and receive items at great heights remove human workers from high-risk areas, but it also allows warehouses to efficiently use up more vertical space.

Source: AutoStore

AS/RSs are most commonly used for order picking and storage — including order consolidation, kitting, and buffering — as well as assembly line optimisation, replenishment and returns. By retrieving and transporting goods between aisles, AS/RSs allow warehouses to cut down on labour and let workers focus on more valuable tasks, such as packaging and posting goods. After having deployed a great number of AS/RSs, retail giant Alibaba reduced its warehouse labour by 70%, thereby skyrocketing their operations and tripling their output.  One downside to AS/RS systems is that they typically take up significant space in the facility. 

Signs that it may be time for an AS/RS include: workers are spending too much time replenishing, travelling or searching for products; there are too many picking errors or damaged items; inventory is misplaced or missing; workers are at risk of getting injured, and; the facility has reached its maximum capacity and cannot keep up with the order demand.

To give you an overview of what types of AS/RSs there are on the market and what cost factors you should keep in mind, we have put our findings together in the table below.

Automated Storage and Retrieval Systems (AS/RSs)
Types	Cost Factors
Vertical/Horizontal Carousels	Amount of clear height available
Vertical Lift Modules (VLMs)	Environment type (ambient, freezer, clean room, etc.)
Crane-based Mini Load AS/RS	Size, quality, and weight of the load to be handled
Vertical Buffer Modules (VBMs)	Which inbound/outbound systems convey inventory
Robotic Shuttles	Current quantity and costs of labour
Floor Robots

As is illustrated in the table above, there are many different types and use cases of AS/RS. This also makes it difficult to determine a specific price range. In fact, the costs of an AS/RS includes the costs of accompanying technologies, equipment, software, controls, installation, delivery, and implementation, too. However, with their ability to automate operational processes — thereby optimising workflows and operational efficiencies — they often provide ROI within 18 months.

Suppliers:

AutoStore

Fabric

Pros and Cons

Based on the information above, we can highlight the following advantages and disadvantages of AS/RSs:

Pros	Cons
1. Reduced Labour Costs	1. Lack of Interoperability
AS/RSs allow warehouses to cut down on labour and let workers focus on more valuable tasks.	Robots from different suppliers cannot communicate with each other and would need a universal fleet management system.
2. Accuracy	2. Size
By improving picking and packaging, these robots increase accuracy through the entire fulfilment process.	Depending on the type and model, AS/RSs can take up a significant amount of space.
3. Improved Inventory Management
AS/RSs help manage inventory, making sure you know what you have and where it is.
4. Improved Safety and Ergonomics
They create a safe and ergonomic working environment.

Articulated Robotic Arms

Articulated robotics arms consist of a multi-jointed limb that can pick up, move, and put down products. They are quite versatile and can be adapted to a wide range of tasks, including picking, packaging, receiving, storing, and vehicle loading. Not only are these robots able to handle duties that are unsafe for humans, but their ability to move heavy and large amounts of inventory in one go also maximises productivity.

Pallets are commonly used to send and receive goods. However, the repetitive nature of the tasks can cause serious injuries among the workers at the facility. Although automated palletising is not exactly a new concept, its increased popularity is highly driven by the desire to make workplaces as ergonomically friendly as possible. Automated palletising is usually carried out by a robotic solution that has an End-of-Arm Tool (EoAT) to grab and position goods on pallets or conveyor belts.

Source: KUKA

AMRs are often used in collaboration with robotic arms, which are used to repeatedly pick products from warehouse shelves. By adding mobility to these robotic arms, AMRs allow the picking arms to transport the goods to different locations. Not only will this give workers time to focus on more valuable tasks, but the collaborative nature of both AMRs and robotic arms also makes them perfectly suited to work alongside human workers.

In addition, most packaging robots come with robotic arm tooling. Just as with many of the above-mentioned tasks, packaging is a very labour-heavy warehouse function that can benefit from automation solutions. Not only can automated packaging systems like bagging machines help speed up the packaging process, but their ability to calculate carton sizes based on orders’ weight and dimensions also helps reduce waste and save time on repackaging orders.

Suppliers:

Kawasaki Robotics

KUKA

Universal Robots

Because of its many different use cases, industrial, articulated robotic arms can cost anywhere from €20K to €330K. These prices are expected to drop by 22% by 2025. However, keep in mind that there are a variety of additional costs such as software, installation, maintenance, etc. Note that non-industrial robotic arms and robotic arms used at schools and universities are on the market for around €800 and less, but these cannot be used in industrial settings.

Pros and Cons

Based on the information above, we can highlight the following advantages and disadvantages of articulated robotic arms:

Pros	Cons
1. Fast, Efficient, and Accurate	1. Need for Technical Knowledge
By improving picking, these robots can optimise accuracy througout the entire fulfilment process.	Employees need the technical knowledge required in order to optimise the robotic workflows.
2. Reduced Labour Costs	2. Need for Constant Monitoring
Robotic arms allow warehouses to cut down on labour and let workers focus on more valuable tasks.	They need supervision to avoid downtime. However, new technology is making it easier to monitor them remotely.
3. Improved Production Capacity	3. Lack of Creativity
Robotic arms are able to produce a significantly higher amount per hour than any human worker.	Robotic arms can only complete tasks as instructed through programming.
4. Improved Safety and Ergonomics
They create a safe and ergonomic working environment.

Automated Guided Carts (AGC)

Coming with minimal features, Automated Guided Carts (AGCs) are the most basic type of AGV. The main difference between AGVs and AGCs is that the latter carry smaller loads. However, they can still carry a wide variety of materials and are commonly used in storage, sorting, and cross-docking applications. Note that — just as AGVs — these robots come in many different forms. The image below shows just a few of the different types of AGCs.

Source: FlexQube

To give some perspective to the initial investment, the table below illustrates the estimated cost of AGCs based on AGC types and navigation technology while considering a load capacity of 1K kg. Note that some AGCs can carry 2K kg, whereas others can only carry up to 500 kg. Prices may differ depending on the AGC’s load and transportation capacity.

Automated Guided Carts (AGCs)
Types (1K kg)	Magnetic or Optical Navigation	Laser or LiDAR Navigation
Unidirectional Towing AGC	€11.5K	€21K
Bidirectional Towing AGC	€19K	€25K
Omnidirectional Lifting AGC	N/A	29K

An example of an AGC application is an automated hospital cart transporter. This way, meals, empty trays, sterile supplies and the like can be transported throughout a hospital in an efficient way. Without the need for human interference, this can also help reduce labour costs. 

Pros and Cons

Based on the information above, we can highlight the following advantages and disadvantages of AGCs:

Pros	Cons
1. Reduced Labour Costs	1. Heavy Initial Investment
AGCs allow warehouses to cut down on labour and let workers focus on more valuable tasks.	While AGCs may reduce costs long-term, the investment is a bit high from a short-term perspective.
2. Safety Improvement	2. Limited Load Capacity
By reducing human involvement, injury rates will decrease.	AGCs can only carry smaller loads.
3. Increased Efficiency	3. Lack of Interoperability
AGCs help reach operational goals in much less time and thereby enhance productivity.	AGCs from different suppliers are not able to communicate with each other.
4. Versatility
AGCs can carry a wide variety of materials.

3. Warehouse Robots for Inventory Management

Thanks to technological advances, some robot types are also able to track inventory levels, complete stock counts, and update the respective information into the WMS.

Autonomous Inventory Robots

Finally, AMRs offer great opportunities for inventory management. By adding Radio Frequency Identification (RFID) tags, the robots will be able to perform inventory checks autonomously, following scheduled tasks determined by the warehouse. Even though autonomous inventory robots come with a heavy price tag of approximately €40K, they help save operational costs significantly by optimising inventories as well as reducing the company’s waste and labour.

The image on the right shows the Autonomous Inventory Robot “Meerkat” from DroneScan.

Source: DroneScan

Pros and Cons

Based on the information above, we can highlight the following advantages and disadvantages of Autonomous Inventory Robots:

Pros	Cons
1. Inventory Optimisation	1. Heavy Initial Investment
Autonomous Inventory Robots can do faster, more frequent, and more accurate inventory sweeps.	While Autonomous Inventory Robots may reduce costs long-term, the investment is a bit high from a short-term perspective.
2. Reduced Labour Costs	2. Lack of Interoperability
They allow warehouses to cut down on labour and let workers focus on more valuable tasks.	Autonomous Inventory Robots from different suppliers are not able to communicate with each other.
3. Waste Reduction
Autonomous Inventory Robots may be able to identify (nearly) expired goods and they help visualise proper product storage.

Unmanned Aerial Vehicles (UAV)

Unmanned aerial vehicles (UAVs), commonly known as drones, combine their flight capabilities with logistics functionality. Drones are often equipped with cameras and RFID scanners for the purpose of checking inventory and stock levels and are able to scan barcodes and monitor inventory levels up to 50% faster than manual scanning and inventory tracking. Their flying capability allows them to easily reach inventory that is stored in high places, which is especially useful for narrow, compact environments. 

Source: doks. Innovation

Their configuration with the facility’s warehouse management system provides real-time data which can help automate replenishment workflows. The system can then assign tasks and issue alerts. For example, if the inventory were to drop below a certain threshold, it would trigger an alert.

They are often also able to lift and move lightweight goods. This can be especially useful for carrying and delivering goods over short distances, creating opportunities for local drop-offs near a warehouse’s facility. Not only would this reduce last-mile delivery costs, but it can also make deliveries more eco-friendly. Even though there is no mainstream use of such drone delivery yet, many tech companies have been working on developing a solution.

Suppliers:

doks. Innovation

DroneScan

FlytWare

Just as with most other robot types, the cost of deploying drones depends on many different factors. These include the size of your facility, the desired frequency of running cycle counting and stock-taking, and the expected accuracy of the inventory counting. Looking at warehouse drones that are currently on the market, the most powerful type of drone for warehousing is currently priced at around €830. Note that there is a difference between consumer drones made for recreational use and drones designed specifically for inventory management.

Pros and Cons

Based on the information above, we can highlight the following advantages and disadvantages of drones:

Pros	Cons
1. Inventory Optimisation	1. Drone Automation is Still in its Infancy
Drones can do faster, more frequent, and more accurate inventory sweeps.	Drone-based automation does not have many proven track records yet and most solutions are still in their validation stage.
2. Reduced Labour Costs	2. Flight Space Required
They allow warehouses to cut down on labour and let workers focus on more valuable tasks.	Drones need space in the facility to fly safely. In some countries, drones cannot fly above people, which limits route flexibility.
3. Improves Scalability	3. Lack of Interoperability
Drones can easily adjust to different environments, making it easier to scale fleets.	Typically, drones are not able to communicate with other types and brands of robots.
4. Data Collection	4. Difficult to Integrate Into Existing WMS
They can easily collect data upon request.	Most WMSs are not drone-friendly yet.
5. Proactive Inventory Management	5. Difficult to Scan Small Items
Drones are able to count inventory on a high frequency based on scheduled tasks.	It may be difficult for drones to scan small objects properly, which might affect inventory accuracy.
6. Lower Human Error
They eliminate the risks of human error.

Something to Keep in Mind

Please note that the prices and specifications mentioned in this article are an approximation and are not guaranteed. It is nearly impossible to calculate the exact price for a robotic system without a detailed project analysis as there are so many variables involved. The final cost of deploying mobile robots will depend on your project’s unique circumstances, which is why we always recommend seeking personal advice from your suppliers.

For additional information on how to start automating your warehouse, we have created a warehouse automation guide, too. Here, you can find a step-by-step overview of how to get started with warehouse automation, how it can benefit your operations, and which areas of your facility are most important to automate.

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About Meili Robots

Meili Robots is developing the next-generation of mobile robots fleet management, called Meili FMS. A universal digital solution, an all-in-one platform that is capable of handling different kinds of Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs). Enable traffic control, empower interoperability and facilitate automated task allocation — all via intuitive UI. Check our website meilirobots.com/product to learn about our products. Contact us to find out more: info@meilirobots.com.

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