Robots vs. Conveyors: Warehouse Logistics Showdown

#Thankfully, the days of manually handling packages in warehouse sorting operations are coming to an end. The introduction of conveyors has made moving items within a facility easier and more convenient, however it is undeniable that they have certain limitations. Conveyors show their limitations when operations quickly expand, space is limited, or when sorting tasks become more complex.

Limitations of Static Solutions

Sorters are the best option for handling large volumes of packages, but for smaller operations or where space is limited, conveyors may Not suitable.

Conveyors are inherently static and inflexible equipment. This means they cannot easily expand their operations without expensive retrofits. For fast-growing markets such as e-commerce, this becomes a barrier. Operators need to consider customer needs in the coming years when selecting conveyors, as equipment can only be optimized once. To overcome this problem, one solution is to use an adjustable conveyor design. This design can be adjusted as needed to meet changing business needs. Using adjustable conveyors avoids expensive modifications and allows for better adaptation to market changes. In this way, operators can expand their business more flexibly to meet customer needs and improve their operations. Space is another factor to consider. Conveyors are often bulky and not ideal when competing for limited space. This problem will be more prominent when the range of destinations for picking or sorting is wide. Using conveyor belts to deliver packages to all of these areas would create a clutter of equipment that would confuse warehouse personnel in an emergency and impede escape. Therefore, when selecting logistics equipment, space constraints as well as work efficiency and safety need to be considered comprehensively.

Conveyor downtime can have a disproportionate impact on sorting operations. If any part of the system fails, the entire process can grind to a halt, leading to delayed deliveries, lost revenue and unhappy customers. Therefore, reducing downtime is important to ensure the smooth running of the process.

The robot is a flexible and non-static device that has proven to be a new and versatile alternative to conveyors, suitable for Various logistics operations. It uses an onboard light detection and ranging system for guidance, which can effectively avoid obstacles and people. All units are able to navigate seamlessly based on a pre-mapped robot operating space.

The robot identifies the intended destination by scanning the barcode on the package and calculates the best route to get there. The entire fleet management system maps the location of each unit and avoids the possibility of crossing with other units to reduce delays. As a result, each robot can travel independently and efficiently to its picking or sorting destination, ensuring excellent flexibility.

The dynamic navigation capabilities of robots give them several advantages over static conveyors. Fleets can easily expand operations by introducing new equipment, making them more adaptable to rapid growth or periods of peak demand than conveyors. Additionally, the robot can be quickly programmed to adapt to new picking or sorting destinations, allowing it to handle both growth and increased complexity.

Robots are ideal for small facilities in sorting operations because they require far less space than conveyors. Additionally, robots have the ability to be easily repositioned, unlike conveyors. Robots are therefore ideally suited to local or temporary facilities set up near delivery points to optimize last-mile logistics.

From a safety perspective, robots are also more popular. Individual robots or entire fleets can be deactivated at the push of a button, eliminating the need for personnel to use large conveyor belts to block potential escape routes if an emergency occurs.

Robots are also sturdier than conveyor belts. A single failed robot can be easily replaced, or other units re-arranged to make up for the shortfall, without stopping the entire sorting operation. Maintenance can be performed and the robot returned to service without interrupting any service, saving time and costs. Ultimately, choosing robots over conveyors can make operations more resilient.

For sorting where high volumes and complexity are factors, robots can easily be used in conjunction with conveyors, combining the strengths of each to overcome traditional pain points in the sorting process. Robots not only overcome challenges but also integrate with fixed infrastructure.

Warehouse operators are now realizing the benefits of robots. In a 2022 study, 23% of businesses surveyed said they were currently using robots in their facilities, with another 21% planning to use robots within the next three years. It is clear that robots will continue to play an increasing role in future sorting operations.