$9K / Mo. Package Lease Fulfills
up to 6,000 Orders/Day

USE CASE: Commerce Warehouse saves $80K/mo

$9K a Month Lease Provides a Complete Robot Solution

Created for midsize warehouses and fulfills up to 6,000 orders a day

Package includes:

  • 10 Robots
  • Shelving & Pick Stations
  • Implementation, software, 24/7 Customer Support and robot maintenance
See what’s in Package

USE CASE: $9K Lease Package is Implemented in an E-Commerce Warehouse

ABC.com’s manual warehouse operation before adding robotics

  • 20,000 sq. ft. warehouse
  • 3,500 orders/day
  • Two 8-hour shifts for Picking and Packing and Receiving
  • One 8-hour overnight shift for Putaway

ABC.com’s goals with automation implementation:

  • Lower operational costs
  • Streamline many processes to become more efficient and improve order accuracy
  • Be able to scale capacity nearly 50% (3,500 to 6,000 orders) when needed in the future

ABC.com’s Monthly Labor Cost of Manual Operation

Labor costs for 46 full-time employees is currently $191K per month
(Based on fully loaded cost incl. insurance, vacation, sick time, training, etc.)

ABC.com’s Manual Warehouse Operation

  • 20,000 sq. ft. warehouse
  • 3,500 orders/day
  • Two 8-hour shifts for Picking and Packing and Receiving
  • One 8-hour overnight shift for Putaway

Order Picking

Picking is performed manually by warehouse workers carrying rf devices and each picker is assigned orders to fulfill. They then walk out into the warehouse to pick the items in the warehouse onto a cart which is then taken to a merging/packing area.

Packing

Manual packing is guided by ChannelAdvisor software. Packers average 20 boxes packed per hour.

Receiving and Putaway

Goods received on pallets and in boxes delivered by trucks from couriers such as UPS freight.  They also receive containers of goods from overseas suppliers. Manned forklifts take pallets off of trucks; currently there is one forklift operator for each daytime shift. In the daytime, received items are stored short term on the loading dock.

The inventory is received into JDA and the four overnight forklift operators put away inventory out into the warehouse aisles where it is stored in two sections, pallet storage or rack storage.

A Look at Operations After Adding Robotic Automation

Monthly Labor Costs Reduced by $80K a Month

  • Headcount reduced from 46 to 23 FTE’s
  • 3rd shift (overnight) eliminated
  • Just 4 Pickers needed, not 24
  • Three Forklift Operators needed, not 6

Picking Labor Cost Reduced by 80%
An 8-hour shift that used to require 12 pickers now needs just two to make the same number of picks. Pickers now remain stationary at a Pick Station, reducing fatigue.

Orders appear on the screen at the Pick Station, and MobileShelf robots automatically bring shelves to the Station containing the items in the order. MobileShelf robots form a continuous queue at the Pick Station, so there’s never a wait for the next item to arrive. It’s possible for a worker to complete up to 300 picks per hour.

Improved Order Accuracy
The Prime Robotics picking system integrates MobileShelf robots with Pick-to-Light and Put-to-Light technologies. Now a worker can simply pick an item, scan it, then put it in a bin. When a pick order is complete, its tote is placed on the Completed Totes Shelf that a robot takes to the packing area when it is full.

Merge Order Process Becomes Efficient
The dilemma of merging order items that are stored in different zones in the warehouse is eliminated entirely, as items no longer have to be stored this way. Now order merging is unnecessary, a complete order can be picked at the Pick Station – virtually eliminating the opportunity for mistakes to happen.

Streamlined Packing Process Means Fewer Errors
The Prime Robotics system’s Packing Station workflows enables ABC to greatly reduce the packing errors that occurred through manual merging process. Now, when a packer calls up the next order on their screen a MobileShelf robot brings the Finished Totes Shelf containing the totes with items to be packed.

Receiving and Putaway Gets Efficient with Robots
Now receiving is the only workflow requiring forklifts  as they unload pallets from trucks to loading dock in the receiving area. The forklift places the pallet onto Prime’s PalletLift, which isn’t a robot, but a simple, mechanized lift that’s can raise a pallet 18 inches off the ground so a MobilePallet robot can drive under the pallet to carry it anywhere.

MobilePallet robots may take a pallet storage area, or inbound  inventory at the new Hybrid Work Station if it needs to be broken down into cases or eaches. A MobileShelf robot takes the inventory into the warehouse aisles.

 Looking Ahead – Now ABC.com can scale when it needs to with no additional cost for robotics

The company has reduced operations to two shifts and is enjoying a savings of over $90K per month as it fulfills its target of 3,500 per day. But if they wan to grow business and increase their daily order fulfillment capacity, they can easily add an overnight shift to increase order capacity nearly 50% without adding any robots or other hardware. Operating three shifts and meeting the goal of 6,000 orders per day using robots equates to a cost savings of $135K versus completing the same order quantity with a manual operation.

MobileShelf - warehouse robotic automation

MobileShelf is the fastest robotic picking AMR solution for warehouses today.

Improve warehouse productivity 8 – 10x over manual picking

  • Workers can make 300-350 picks per hour
  • Dramatically reduces demand for manual labor
  • Training is fast and it’s easy to operate
  • Deploy with minimal operation disruption

MobileShelf + Warehouse Optimization Expertise + our proprietary Prime Workflow Builder allows us to achieve higher productivity.

See MobileShelf in Action
Warehouse Robotic Automation MobileShelf

MobilePallet warehouse robotic automation

Automate pallet moving to increase warehouse efficiency.

  • Dramatically reduce demand for forklifts and number of human touches.
  • MobilePallet and MobileShelf can work in concert to create a highly efficient automated warehouse.
See MobilePallet

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Steve Hobbs,
Director of Sales

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