What is autonomous material handling and how to leverage it today

Warehouses are more than just storage facilities for goods in transit.

They are places where material handling systems critical to the supply chain work to accelerate the movement of goods.

These systems rely on complex processes that are rapidly evolving by adopting new technologies to enhance efficiency, increase productivity, and reduce workplace accidents.

Autonomous mobile robots (AMRs) are the latest evolution in material handling technology. If you want to learn how autonomous material handling fits into the material handling ecosystem and what challenges it solves, you’re at the right place.

What is material handling?

Material handling refers to the movement, storage, retrieval and shipping of goods and materials to and from specific locations.

Most commonly used in warehousing, material handling employs various techniques, equipment, systems, and technologies to facilitate manual and machine assisted labor in both loading and unloading operations.

Material handling technology can vary from simple techniques such as using funnels to easily store loose goods, to advanced autonomous systems that work alongside warehouse staff.

What is autonomous material handling?

Autonomous material handling employs advanced autonomous mobile robots (AMRs) to assist in the movement of goods.

AMRs are equipped with sensors, high-definition cameras, and fast onboard processors that run advanced AI vision and context algorithms. These systems help autonomous mobile robots, such as autonomous forklifts, to navigate warehouses and perform tasks with full independence.

This represents an upgrade over automated guided vehicles (AGVs), which require set paths, whereas AMRs can map their paths in real time to optimize their routes.

Benefits of autonomous material handling

AMRs are designed to work alongside and amongst warehouse operators. The benefits of employing AMRs in warehouse environments include:

• Improved safety: AMRs employ systems designed to improve worker safety and reduce workplace accidents in warehouses. Keep in mind, the number of fatalities in US warehouses has been rising since 2020, with 46 fatalities in 2021 and 50 in 2022, double the numbers from 2020 and prior years. It is a dangerous industry.
• Maximize productivity: One worker can handle multiple (un)loading AMR, freeing up valuable time they can use to focus on higher-value operations.
• Increasing process stability: AMRs operate in a very predictable manner which allows for improved scheduling and enhanced stability across material handling systems.

These are just a few general benefits of employing autonomous mobile robots in material handling systems. AMRs are designed to address the chronic challenges in material handling.

What are material handling challenges and how do AMRs solve them?

At the root of AMR design is the idea to improve material handling efficiency by solving specific challenges in the industry. This makes AMRs invaluable in material handling operations in warehousing and logistics.

These are some of the key material handling challenges that AMRs solve:

Safety

Autonomous forklift companies develop AMRs with cameras and other sensor suites, such as LiDAR, with safety in mind. These technologies allow autonomous forklifts and other AMRs to safely and independently plot their own courses while being observant of potential threats to workplace safety with 360° contextual awareness. This full situational awareness supersedes human ability, providing for safer workplaces.

Further, in material handling, heavy or hazardous materials pose considerable safety risks to human workers. With autonomous material handling, AMRs can take over these potentially dangerous tasks and materials to reduce the risk of workplace injuries, thus creating a safer work environment.

Labor shortages

Labor shortages are a challenge in any industry, but with the high level of expertise and skills required for material handling, this can be especially problematic. AMRs can solve this ever looming material handling challenge by performing tasks that need human workers. This way, material handling operations can run smoothly, even if there are not enough workers available.

High labor costs

Labor costs have been rising steadily each year at around 5% per year. AMRs can help you curb labor costs in material handling by automating repetitive and time-consuming tasks. This helps optimize task allocation by freeing up human workers to tend to more complex, value-added activities.

Scalability

Scaling up operations as your business grows can be difficult when employing solely traditional material handling systems.

However, AMRs facilitate scalability by allowing warehouses to easily add more robots to their operation. This helps them to quickly and easily manage increased workloads without significant infrastructure changes.

Operational inefficiencies

Manual material handling can sometimes be disorganized due to the simple fact that it relies only on humans. When you share that burden and have AMRs working in tandem with humans, you get more scalability and efficiency.

By leveraging AMRs you don’t only minimize costly and time consuming errors, you also get the upper hand when it comes to organizing your operation. By fully automating processes, such as loading and unloading, you will be able to more accurately predict the duration of your dock operations.

Adapting to changing environments

Traditional material handling systems can struggle to adapt to dynamic environments – i.e. operations where layouts frequently change.

But AMRs, with advanced navigation and mapping capabilities, easily adapt to new layouts in real time to maintain operational efficiency.

Managing inventory

Manual inventory tracking can result in costly and time-consuming discrepancies.

However, AMRs can update records in real time by continuously monitoring stock as they work, to ensure accurate and up-to-date inventory lists.

Dependable order fulfillment

Manual material handling processes can struggle to keep up with customer expectations for fast order fulfillment, especially during unexpected peak periods.

Introducing autonomous material handling with AMRs helps you increase the reliability of your operation, ultimately improving customer satisfaction.

The future of autonomous material handling at the loading bay

By design, AMRs directly address these chronic material handling challenges. Autonomous forklift companies developed AMRs like these with the goal of enhancing the efficiency, accuracy, and safety of material handling processes in warehousing and logistics, and helping the supply chain move.

Autonomous forklifts like Trey, developed by Gideon with the goal of solving a unique challenge deemed unsolvable – trailer loading and unloading, promise to save time while improving safety.

Industry leaders have recognized the potential automated material handling brings to their operations and the value that the technology represents to them and their customers.

Is it hard to implement AMRs?

Many companies are reluctant to invest in such technology and give it a try. And, while sound, the logic behind such reasoning is outdated.

Implementing AMRs comes nowhere near the costs of implementing other automation technology. This is because a lot of them, like Trey, are designed to be a plug-and-play solution you can implement in your current operations – without needing to develop and invest into expensive infrastructure or extensive training.

Josip Cesic, Gideon’s CEO, talked in-depth with Prologis about how Gideon addresses the challenges we mentioned above and, more importantly, explained how implementing Gideon’s AMRs into your loading bay is not an all or nothing decision. Incremental automation is possible.

Get in touch with us for more information on our pilot program. And, if you haven’t yet, click the button below and meet Trey, the autonomous forklift.