Affordable Robotic Solutions: Revolutionising the Promotional Products Warehouse

Introduction 

In the evolving landscape of warehouse operations, robotics and automation have become essential for enhancing efficiency and productivity. While only about 20% of the world’s warehouses are currently automated, advancements in technology have made robotics more affordable and accessible. The rise of Robotics as a Service (RaaS) allows companies to implement robotic solutions through a subscription model, reducing upfront costs and enabling flexible scaling. Improvements in AI and sensor technology have further enhanced the efficiency and reliability of these systems, addressing challenges like rising labour costs and fluctuating demand. As a result, warehouse robotics is not just a competitive advantage; it represents a strategic investment in the future of supply chain management. 

Benefits of Warehouse Automation 

Increased Productivity and Throughput: Robotics automate menial tasks and optimise pick paths, significantly accelerating order processing and improving accuracy. 

Long-Term Cost Savings: The initial investment in automation can be substantial, but as it reduces the need for manual labour, human resources can either be reduced or focused on more valuable activities. This shift not only saves money but also increases efficiency and consistency.  

Optimised Space: The robotic ability to navigate vertical storage spaces and narrow aisles means the availability of storage space is maximised, which is especially advantageous for promotional product companies with a diverse inventory. 

Safety and Sustainability: If potentially hazardous tasks are being handled by robotics, worker safety is enhanced. Sustainability is also improved as energy-efficiency is improved by reducing power consumption and minimising waste. 

Enhanced Worker Safety: Working at height and handling heavy loads are common causes of industrial injuries. For example, forklifts have an 11% accident rate. The implementation of automation can reduce strain on workers, demonstrating how advanced workstations are designed with human operators in mind.  

Robotics for Packing and Sorting 

Automated Guided Vehicles (AGVs) for Material Transport 

AGVs navigate pre-determined paths marked by lines, tracks and wires, some using SLAM (simultaneous localisation and mapping) technology to move freely and adapt to environmental changes. Robots can safely operate alongside human workers, detecting and manoeuvring around obstacles with their in-built sensors. They connect to a central software that sends instructions and receives updates, optimising efficiency. This is where further enhancement is possible by integrating them with a warehouse management system (WMS). 

Robotic Arms for Picking and Packing 

Automated cartonization software determines the most efficient box size for a given set of items, minimising waste and reducing material costs. Bagging robots automate the process, rapidly inserting items into bags, sealing and preparing for shipping.  

What’s out there? 

• KUKA DELTA Robot: Ideal for picking and handling small items with a stainless steel body suitable for hygienically sensitive areas. It offers a wide range of motion and high precision. 

• inVia Picker: Small, safe and easy-to-use robot that assists fulfilling orders. The company offers a robotics-as-a-service (RaaS) business model, reducing implementation barriers.  

Implementation Considerations 

Initial investment and ROI: The cost of these systems can vary; basic systems start around £40,000 but more advanced solutions can cost several hundred thousand. RaaS offers an accessible alternative, allowing businesses to lease robots and pay as an operational expense instead.  

Integration with Existing Systems: Comprehensive implementation requires integration with existing warehouse management systems. Staff training and upskilling are essential to address staffing concerns and job shifts from labour to supervision and maintenance. 

Opportunities for Employee Growth: Whilst there may be concerns about job loss, automation allows storage operations to scale on demand. Uniquely human skills such as creativity and dexterity will increase in value as routine tasks are automated, allowing for employee growth in technical skills.  

Case Studies 

PUMA have successfully implemented robotics in their warehouse operations, using a solution from the company AutoStore. They have found it has significantly improved employee satisfaction, with their global logistics director commenting: ‘Now we can see people are proud of working in an AutoStore environment, which is clean and technology-driven’.  

Looking Forward 

Emerging technologies in warehouse automation continue to evolve, offering new opportunities for the promotional products industry. This presents numerous benefits: increased productivity, cost savings and enhanced safety. The initially investment might seem steep, but the long-term advantages make it a worthwhile investment. Exploring the world of robotic automation will help to stay competitive in the industry whilst meeting the demands of the modern workspace.