What are autonomous mobile robots (AMRs)?

What are autonomous mobile robots (AMRs)?

Autonomous mobile robots are sophisticated mobile devices designed to seamlessly navigate warehouses and fulfillment centers. Unlike their predecessors – the autonomous guided vehicles (AGVs), which rely on external guidance mechanisms and predefined paths – AMRs operate without such constraints.

The agility and efficiency of autonomous mobile robots make them indispensable in modern logistics.

Navigation autonomy

AMRs can move through the warehouse without relying on physical tracks or electro-mechanical guides, making them adaptable to changing conditions in real time.

Sensor-empowered mapping

Equipped with advanced sensors and cameras, AMRs construct a digital map of their surroundings, enabling them to move freely and safely within a facility.

Dynamic adaptation

AMRs dynamically adjust their paths, seamlessly avoiding collisions and maneuvering around obstacles. This adaptability means they can access a wider range of locations more quickly, ensuring uninterrupted operation even in the most complex settings.

A growing market

By 2025, the AMR market is set to grow by 45% (CAGR 2022-2025).

Why autonomous mobile robots are essential

The last few years have seen a huge rise in eCommerce, creating a host of new challenges for the supply chain industry. Ever-increasing demand for rapid delivery, alongside an increase in stock-keeping units (SKUs), requires more flexible and scalable fulfillment. However, with insufficient labor resources, traditional scaling methods are impracticable. Manual operations are also cost-prohibitive, inefficient and prone to errors.

The following challenges are pushing logistics managers to seek creative technological solutions:

Labor shortages

Globally, labor shortages, particularly in manual roles, present a significant barrier to growth. This issue intensifies during seasonal peaks or unexpected surges in demand, where short-term temporary labor not only incurs higher costs but also requires a considerable period to reach peak productivity.

Seasonal peaks

Warehouses face a variety of challenges during seasonal peaks, ranging from the recruitment and training of temporary staff to meeting elevated customer expectations within shrinking delivery timeframes. An inability to manage these peaks can exacerbate existing operational challenges, leading to inefficiencies and disruptions.

Need for scalable and flexible solutions

The dynamic nature of warehouse operations demands adaptable solutions. Traditional automation offers substantial efficiency gains but often involves significant upfront investment and inflexibility, making it less viable for small and medium-sized businesses or operations looking to scale alongside their growth.

KPI improvements

Operations are continuously seeking ways to enhance key performance indicators (KPIs), such as productivity and accuracy. Even marginal gains in these areas can have a profound impact on overall performance, driving the adoption of technological solutions.

What tasks can an autonomous mobile robot perform?

Autonomous mobile robots (AMRs) serve as dynamic facilitators in the warehouse, enhancing logistics and overall efficiency. Designed to augment rather than replace human labor, warehouse robots are deployed for the most monotonous, time-intensive and hazardous tasks.

AMRs can handle a number of warehouse responsibilities, such as:

• Piece picking
• Put-away and replenishment
• Bulk material movement
• Component shuttling
• Sortation

They can also enhance operational flow through the following advanced methodologies:

Swarming

Using a fleet of coordinated robots in the warehouse, swarming optimizes the picking process by minimizing worker movement. AMRs, directed by the warehouse management system (WMS), meet workers at designated picking locations to ensure that items are collected efficiently, and the flow of goods is uninterrupted, enabling pickers to focus on selecting items without the need for cart-pushing or extraneous tasks.

Follow the bot

This method involves workers pairing with a robot that guides them along the optimal picking path. After completing a pick, the worker seamlessly transitions to another robot, ensuring a continuous and streamlined picking process without the downtime of traditional methods.

Goods to person

In this approach, warehouse robots transport mobile shelves of products to stationary pickers. Workers remain in one place and pick items as robots present them, significantly enhancing picking speed and reducing the physical strain associated with moving through the warehouse.

Person to goods

Person-to-goods autonomous mobile robots – also known as co-bots – support workers as they travel through the aisles, picking items one by one to complete a specific order. As well as reducing travel and congestion around the warehouse, these AMRs eliminate picker start and end tasks.

What are the benefits of using AMRs?

Compared to manual operations, or a traditionally automated environment, the use of robotics can help improve operational efficiency – giving the warehouse the ability to do more with less.

From improving floor operations, transportation and processing to generating warehouse layout reports, robotics offers huge advantages for efficiency, growth, scalability and speed.

Increased productivity

Autonomous mobile robots improve workforce efficiency by cutting down on movement between locations. The simple AMR interface also makes the picker’s job easier and more enjoyable, significantly boosting productivity, particularly for new workers.

Reduced errors

With their visual interfaces, AMRs provide workers with detailed information about each product they need to pick, including its appearance and where to drop it. This minimizes human-related picking errors and, therefore, customer dissatisfaction. Also, by recognizing the SKUs and where in the system the products are placed, robots can improve stock control. This same inventory-tracking capability enhances traceability – essential for safety and quality control in the food and beverage industry.

Adaptability

Autonomous mobile robots adapt to your warehouse system and environment, offering the best solutions for your needs. They can optimize product placements on shelves, for example, by identifying movement opportunities.

Scalability

An AMR solution can be easily scaled up or down to match fluctuations in demand, reducing the need for additional seasonal or temporary staff.

Operational efficiency

Autonomous warehouse robots can improve operational efficiency by handling put-away, replenishment, bulk material movement, component shuttling, goods-to-person tasks, piece picking and sorting, thus reducing manual labor and optimizing manufacturing processes.

Facility optimization

Autonomous mobile robots can help businesses get more out of their operational space, often without major changes to layout or function. They also reduce staff walking distances, optimize pick paths and improve pick area flow.

Labor shortage mitigation

By taking over routine tasks, especially during peak seasons, AMRs reduce the need for extra temporary labor. Moreover, they cut training time, guiding workers to picking locations without them needing to learn the warehouse layout. Mobile robots also free existing staff to concentrate on more critical aspects of the workflow, thereby optimizing the use of skilled labor.

Reduced costs

During peak times, autonomous mobile robots can reduce operational costs by decreasing staff overtime and taking over some manual tasks. This also means less time spent training new employees.

Affordability

The Robotics-as-a-Service (RaaS) model enables businesses to lease AMRs according to demand, supporting cost-effective scalability and eliminating the need for permanent investment in automation infrastructure.

Easy integration

AMRs can often be deployed and incorporated into existing operations with little to no infrastructure modification and minimal disruption, helping to reduce the cost of automation and accelerate the time to value. Some warehouse robots are capable of quickly learning and adapting to their surroundings.

Benefits at a glance

• Real-time visibility into warehouse workers, labor costs, response times and productivity gaps, so businesses can take steps to become more efficient
• Faster and more accurate goods in, put-away and returns by scanning an RFID barcode
• Real-time view of inventory through automatic identification and data capture  technology, so you can keep minimal stock levels to meet customer demand
• Inventory tracking, ensuring the right goods arrive in the right quantity and enabling them to move faster through the warehouse
• More streamlined picking, packing and order fulfillment, optimizing picking paths through technologies such as pick-to-light, pick-to-voice and robotics
• Yard management, helping drivers find the right loading docks and cross-docking where needed
• Automatic generation of bills of lading, packing lists, shipment invoices and notifications
• Real-time visibility into transportation and shipping activities
• Analytics and reporting on metrics such as on-time shipping, inventory accuracy, distribution costs and order cycle time

How autonomous mobile robots aid micro-fulfillment

AMRs facilitate the transition to micro-fulfillment by enhancing efficiency, flexibility and scalability. This makes them integral to meeting the demand for rapid online order fulfillment in accessible, small-scale warehouse facilities.

Increased efficiency and throughput

AMRs can significantly boost the speed and accuracy of picking operations, enabling retailers to achieve throughput rates of 400% or more. This efficiency is crucial for meeting the quick delivery expectations of online consumers.

Flexibility and scalability

With flexibility and a low barrier to entry, AMRs enable retailer to rapidly adapt to changing levels of demand. They can be easily integrated into various environments, including non-traditional fulfillment spaces like retail stores, due to their compact size and maneuverability.

Optimization of existing spaces

AMRs can operate effectively in urban micro-fulfillment centers, often with minimal modification. Their ability to work in tight spaces makes them highly suitable for most fulfillment operations.

Agile solutions for seasonal demands

The agility of AMRs to cope with fluctuating demands, such as seasonal peaks, without requiring fixed infrastructure is a significant advantage. They provide the capability to scale operations up or down as needed.

Integration with current retail sites

AMRs can be used alongside existing retail operations, offering a seamless solution that enhances online order fulfillment without disrupting in-store activities. This dual functionality is particularly useful for retailers looking to maximize their footprint.

Speed of implementation

Compared to traditional fixed automation solutions, AMRs can be implemented quickly, often within weeks. This rapid deployment allows retailers to adapt swiftly to evolving consumer expectations.

The myths of autonomous mobile robots

As AMRs gain popularity, misconceptions about their capabilities and limitations will likely arise. Here's the truth behind ten common myths:

Job replacement: Unlike some automation technology, AMRs are designed to collaborate with staff, enhancing productivity by taking on repetitive tasks.

Complexity: AMRs are user-friendly and require no more training for warehouse staff than other new technological integrations.

Cost prohibitive: AMRs are becoming increasingly affordable and can be acquired via Robot-as-a-Service (RaaS) models, aligning with various budget constraints.

One-size-fits-all: AMRs come in many forms and can be specialized for different workflows and specific industries.

Single-vendor limitation: You can deploy AMRs from multiple vendors within one warehouse, assuming the right strategies and integrations are in place.

Safety concerns: Equipped with advanced sensors, AMRs are safe and often decrease the number of warehouse incidents by reducing human error.

Industry maturity: AMRs are an advanced step on from AGVs, offering greater navigation freedom and technological integration.

Refrigerated environments: Despite the challenges, AMRs are reliable within consistent refrigerated or chilled environments.

Incompatibility with voice: AMRs can be used in conjunction with voice technology, combining the benefits of both.

Universal applicability: While AMRs have certain operational requirements, they are more adaptable and less challenging to deploy than traditional automation systems.

What should you look for in an AMR solution?

When selecting an autonomous mobile robot solution for your warehouse or logistics operations, consider the following:

Comprehensive SKU handling

Ensure the AMR system you select can accommodate all your SKUs, taking into account the variety in weight, shape and complexity. This is particularly vital in sectors like FMCG, third-party logistics, and the grocery and food retail space, where diversity in stock can be extensive.

Scalability without increased footprint

Your chosen autonomous warehouse robots should be capable of scaling up in line with your operation's growth, without necessitating a proportional increase in physical space. This allows for a flexible response to fluctuating demands without over-investment in under-utilized capabilities.

Seamless IT integration

Opt for an AMR solution that integrates effortlessly with your current WMS. Whether you require a comprehensive turnkey solution with complete software and controls, or something that can merge into an existing warehouse control system, compatibility is key.

Futureproofed investment

In a rapidly changing supply chain landscape, it is essential to find an AMR system that can support increased order volumes and product diversity. Look for modular designs that facilitate easy enhancements and provide access to ongoing updates and expansions.

Comprehensive digital services and support

Autonomous mobile robots should be part of a larger digital ecosystem that includes essential services to optimize cost-efficiency, maximize uptime and provide prompt resolution of issues. Comprehensive support, including training, digital remote servicing, and continuous upgrades and retrofits, is critical to leverage the full transformative potential of your investment.

Who should invest in AMRs?

Autonomous mobile robot solutions can improve the efficiency of supply chain operations of all sizes. But, as an indication, eCommerce, retail, omnichannel and wholesale fulfillment centers of conveyable goods with 5,000 or more SKUs per day and five or more pickers per shift can benefit from Layer Picker AMRs. Manufacturing, distribution, fulfillment and warehousing customers using fork trucks for movement over at least two shifts per day can also benefit.

But volume is not the only consideration when justifying investment in autonomous warehouse robots. It is also important to factor in the variety and the type of SKUs that need to be handled (e.g., weight, size and fragility), as well as the warehouse environment (e.g., ambient, chilled or frost) and future fluctuations in product types and packaging. Product mix and availability, in combination with cost of labor and warehouse capacity, can also determine whether expected volumes can justify an automated solution.

Choosing the right system dimensioning is crucial too. You will need to work closely with your systems partner to tailor the automation solution to the specific needs of your warehouse. This often involves analysis of your current processes and production data – e.g., customer order data, material flow and production requirements. By drawing on real data you can create visual simulations to test maximum capacities and identify potential bottlenecks, helping to refine and finalize the design before implementation.

Autonomous mobile robots case studies

Boxy: State-of-the-art eCommerce fulfillment 

Boxy, a leading logistics service provider for online retailers in Hungary, demonstrated how integrating an advanced WMS with autonomous robotics can significantly improve eCommerce fulfillment operations.

• Operational improvements – Boxy saw a 233% increase in picking performance to 300 picks per hour per workstation and the capability to sort up to 1,300 packages per hour.
• Cost and delivery benefits – Boxy was able to offer up to 50% cost savings to its clients, extremely short lead times and same-day delivery within the greater Budapest area.
• Technology and integration – The combination of the WMS, Unified Control System (UCS), and Shipping & Dispatch System (SDS), integrated with robotics solutions, optimized goods-to-person and parcel sortation.
• Efficiency and scalability – The solution was rolled out with minimal training and is designed to accommodate additional autonomous mobile robots without significant infrastructure changes.

Evo: Enhancing retail and distribution with robotics

Predominantly online-based winter sports apparel business Evo had expanded their warehouse ahead of an unprecedented surge from the holiday season and the global pandemic. An autonomous mobile robot solution was crucial to support the evolving market demands.

• Picking efficiency – Evo successfully increased picking speed from 35 to 90 units per hour while maintaining mixed SKU handling in a single bin for optimized picking accuracy.
• Staff optimization – A reduction in staff from 12 to 5 mitigated congestion and enhanced workflow within the warehouse.
• Peak season adaptation – The adoption of 7 additional robots during peak periods through a RaaS model ensured that Evo could scale operations without unnecessary long-term expenses.
• Operational reliability – The solution maintained a virtually error-free record, thus securing operational continuity and reliability.
• Expedited staff training – New or temporary staff were trained in 10-15 minutes, ensuring that the warehouse remained productive.
• Employee morale – Staff viewed the technological aid as a support rather than a substitute, leading to enhanced morale.

What does the future of AMRs look like?

As customer demand continues to grow, the need for flexible warehouse solutions has become ever more pressing.

Meanwhile, the autonomous mobile robot industry is seeing a rapid expansion of its own, which is making the technology more affordable and easier to integrate. Furthermore, as the software grows more sophisticated, these robots will be able to take on additional tasks.

In the dynamic logistics environment, mobile robots are becoming more common. To remain competitive, warehouses must select AMRs that complement their unique operational needs. By delegating routine tasks to AMRs, warehouses can leverage these tools to enhance efficiency and drive new business opportunities.