Automated Warehouse Management with Robotics Integration

AutoStore operated a 500,000 sq ft distribution center processing 12,000 orders daily but struggled with labor shortages, slow manual picking (averaging 80 units/hour), and inventory inaccuracies. Peak season demands exceeded capacity, forcing expensive outsourced fulfillment. The company needed to triple throughput while reducing operational costs.

The solution required integrating autonomous mobile robots for picking and transport, orchestration software managing robot fleet coordination, real-time inventory tracking with RFID, integration with existing WMS and ERP systems, and a control dashboard for warehouse managers. The system needed to coexist with human workers during transition phase, requiring robust safety protocols.

We implemented a fleet of 45 autonomous mobile robots from Locus Robotics, integrated with a custom orchestration platform built on ROS (Robot Operating System). The platform coordinated robot assignments, path planning, charging schedules, and collision avoidance using real-time positioning via ceiling-mounted QR codes and LiDAR sensors.

The WMS integration layer connected robots with the existing Manhattan Associates system, receiving pick lists and updating inventory in real-time. RFID gates at shipping stations automatically verified order accuracy, reducing mispicks to near-zero. The web-based control dashboard (React + Node.js) provided real-time fleet visibility, performance analytics, and manual override capabilities.

The automation transformed warehouse operations, enabling 24/7 operation with 40% fewer staff while processing 3x order volume. Robot fleet orchestration optimized 45 AMRs working simultaneously without collisions. Order fulfillment time dropped from 4.5 hours to 72 minutes. The ROI was achieved in 18 months through labor savings and increased throughput capacity.