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Updated on 10 dec 2024 • 10 min read

AMRs: How Automated Manufacturing Robots Optimise Logistics Operations

Material & Logistics TransportsuLog Series

CLARISSE LE GUYADER

Head of Marketing for public life robots - Hospitality & Retail, Healthcare and Education sectors.

AMRs: How Automated Manufacturing Robots Optimise Logistics Operations

Labor shortages impact 76% of logistics operations, according to a study by Descartes Systems Group. This challenge puts added pressure on businesses to enhance operational efficiency. At the same time, automated manufacturing robots (AMRs) are gaining traction in automating logistics and intralogistics processes. On one hand, they reduce employees' workload; on the other, they address the labor shortage in physically demanding jobs. Unsurprisingly, their adoption is growing rapidly in industries such as manufacturing, logistics, and healthcare. Currently, the global AMR market is valued at $3.88 billion in 2023. According to Research and Markets, it’s projected to reach $9.56 billion by 2030, with an annual growth rate of 15.3%. This trend underscores their critical role in addressing the rising demand for automation and flexibility.

Article Highlights

Overview of Production and Logistics Chains

Current production chains are complex systems. In an automotive factory, a production line may involve over 20 distinct steps. It manages everything from sourcing raw materials to delivering finished goods. Here’s how it works:

How Production Chains Work

Sourcing: companies source raw materials from domestic or international suppliers. Effective management is crucial to prevent stock shortages.
Production: raw materials are turned into finished goods through manufacturing, assembly, and quality checks.
Storage: completed items are stored before shipping. Smart inventory management allows companies to quickly meet demand while minimizing excess inventory costs.
Distribution: goods are then shipped to end customers.

Gaps and Challenges in Production Chains

In production chains, supply delays and equipment breakdowns are common. A study by McKinsey Global Institute shows that without advanced automation, companies struggle to achieve peak productivity.

Inefficiencies also arise in parcel management. Incorrect sorting sends goods to the wrong destinations, leading to costly returns. Tracking errors, such as inaccurate information about a parcel’s status or location, complicate planning and extend processing times.

Additionally, supply chains often lack visibility. Data on inventory, shipments, or delivery times isn’t always available in real-time. This information gap prevents businesses from anticipating issues or quickly adjusting their operations. As a result, stockouts can cause an 8% to 15% loss in sales.

Finally, rigid systems that cannot adapt to demand fluctuations or market changes hinder business responsiveness.

Challenges in Managing Logistics Flows and Material Transportation

Modern supply chains face growing challenges in managing flows and transporting materials.

Shortage of skilled labor: The logistics sector is grappling with a shortage of skilled labor, impacting operational efficiency. An aging workforce and inadequate training programs have left businesses struggling to meet the growing demands of modern logistics.
Technological advancements now require precision and adaptability, skills often lacking in an unprepared workforce. By addressing these challenges and adopting systems that handle repetitive tasks, companies can boost productivity, reduce workforce strain, and enhance safety. Those changes will allow employees to focus on higher-value activities and drive growth in a competitive market.
Ergonomic issues and injury risks: Musculoskeletal disorders remain one of the most pervasive concerns impacting the workforce across industries, especially in physically demanding sectors such as logistics and manufacturing. These disorders are the leading causes of disability, early retirement, and limited employability.
In 2018, there were 900,380 cases of Days Away From Work (DAFW) reported in the private sector in the United States. Of these, 272,780 cases—or 30% were attributed to MSDs. These injuries are particularly debilitating, with each case resulting in an average of 12 days away from work.
The financial impact is staggering. According to NCS, injuries caused by overexertion alone cost U.S. employers $13.3 billion annually. When combined with other factors such as absenteeism, presenteeism, turnover, and difficulties in attracting new talent, the cumulative costs of MSDs escalate significantly.
Inefficiency of manual operations: Manual operations in logistics, such as sorting and moving goods, are susceptible to errors and delays. A conference paper by Wroclaw University of Science and Technology highlights that human errors disrupt workflows and reduce service levels.
High costs of delays and errors: logistics mistakes and delivery delays result in additional expenses, wasted time, and resources.

AMRs provide the solution to address the shortage of skilled labor and inefficiencies in manual operations.

What are AMRs?

AMRs are handling robots that navigate autonomously and perform various tasks. These robots use advanced sensors, such as cameras and LiDARsystems, to move around. These technologies enable them to analyse their environment in real-time.

Using SLAM technology, they also map their surroundings while adjusting their paths. This allows them to avoid obstacles and optimise their movements.

Differences between AMRs and AGVs

AMRs are far more flexible than AGVs. AGVs (Automated Guided Vehicles) follow fixed paths using physical markers, like magnetic strips. In contrast, AMRs navigate freely and adjust their routes in real-time.

This flexibility is essential in environments like warehouses. Why? Because routes often change based on orders and operational needs. AMRs adapt to these changes without requiring costly modifications.

Advantages of AMRs in Industrial Environments

AMRs offer numerous benefits for businesses utilising industry automation solutions to optimise their workflows:

Operational flexibility: AMRs can be reprogrammed quickly to handle changes in tasks and routes. This makes them valuable for dynamic environments that rely on advanced picking robots to manage logistics effectively.
Cost reduction: these robots eliminate the need for physical guidance systems. They also reduce reliance on labor for repetitive tasks, such as sorting or transporting, which are traditionally handled by transport robots.
Enhanced safety: AMRs’ sensors detect obstacles with precision. This capability reduces accidents, especially when using robotic lifting devices to handle heavy or awkward loads safely.
Improved efficiency: autonomous material transport streamlines workflows.

Efficiency Gains and Reduced Production Times

The adoption of autonomous manufacturing robots and advanced automation solutions boosts productivity and flexibility for manufacturing companies. Bosch, a pioneer in Industry 4.0, is a notable example. In its factories worldwide, including in Germany, the United States, and China, the company has connected over 120,000 machines and 250,000 devices.

This connectivity enables real-time monitoring and continuous production optimization. Thanks to automation, Bosch has cut process times and increased delivery capacity by up to 25%.

Error Reduction and Improved Visibility

AMRs help minimise human errors in parcel management and inventory tracking. The integration of advanced technologies enhances accuracy within logistics workflows.

Adaptability to Demand Fluctuations and Cost Reduction

Unlike rigid systems, AMRs offer the flexibility to be reprogrammed for new tasks or routes without requiring significant structural modifications.

Siemens implemented advanced automation solutions within its production lines, showcasing the potential of AMRs and similar technologies. Through this integration, the company was able to achieve a 15% reduction in operational costs. Additionally, Siemens reported significant improvements in data accuracy, which enhanced its ability to make informed decisions and optimise production capabilities across its facilities.

Improved Working Conditions and Reduced Risks

AMRs handle physically demanding tasks, thereby reducing the risk of injuries. This not only lowers costs associated with musculoskeletal disorders but also minimises absences due to workplace accidents.

To meet business needs, United Robotics Group (URG) has adopted a hybrid approach, with in-house development paired with best-in-class technology selection for quick market adaptation, resulting in the uLog series. This series represents a new generation of autonomous mobile robots. These AMRs are designed to optimise transport, lifting, and flow management tasks in various industrial environments.

We now present the robot’s features.

Features of uLog AMRs

These new handling robots combine advanced sensors and intelligent software. They navigate accurately while interacting with existing systems, such as WMS.

Smart navigation:LiDAR sensors and SLAM (Simultaneous Localization and Mapping) algorithms enable navigation without fixed infrastructure. The robots detect and avoid obstacles in real time. They operate even in dynamic environments where routes frequently change.
Modularity: uLog robots handle light loads, heavy loads, or pallets depending on requirements.
Easy integration: they work with leading warehouse management systems (WMS) and ERP software. Their onboard system is compatible with SAP, Oracle, and Microsoft Dynamics. This compatibility simplifies operations coordination, optimising workflows.

Applications of uLog Handling Robots

uLog AMRs help modernise logistics and production operations. Here’s how:

Warehouse Management:

Autonomous transportation of parcels between storage areas and loading docks.
Replenishment of picking zones for faster order preparation.
Automated inventory tracking using onboard sensors.

Industrial Production:

Supplying production lines with necessary materials is made easier with advanced pallet robots..
Moving finished products to storage or shipping areas.
Assisting assembly tasks by transporting components.

Distribution Logistics:

Automating flows between departments within a distribution centre.
Handling returns by sorting and transporting products to processing zones.
Reducing cycle times for shipments.

Healthcare Sector:

Autonomous delivery of medications, medical supplies, and equipment to various hospital departments.
Collecting and transporting linens or medical waste, reducing human movement.

Retail:

Automatically restocking shelves in physical stores.
Supporting inventory management in warehouses dedicated to e-commerce.

uLog Series Overview: the Different Robots Explained

The uLog series from United Robotics Group offers a diverse range of automated manufacturing robots designed to meet varied operational needs.

uLog DELIVER: Automating Internal Deliveries

The uLog Deliver optimises internal goods flows within industrial and logistics facilities. This industrial autonomous robot excels at repetitive deliveries across different areas of a site.

Key Applications:

Autonomous transport of small to medium loads between workstations or production zones.
On-demand delivery of supplies or materials directly to employees.
Reducing human movement in warehouses and factories.

Key Features:

Autonomous navigation powered by LiDAR sensors, enabling real-time obstacle avoidance.
Automated loading and unloading enabled by seamless integration with other robotic systems.

uLog LIFT: Autonomous Heavy Load Handling

The uLog Lift transport and heavy lifting robot supports logistics operations involving heavy loads. Its robustness and precision make it ideal for transporting pallets or containers in industrial environments.

Key Applications:

Transporting heavy loads, such as pallets or bulky equipment, within warehouses and distribution centres.
Reducing physical strain on employees in production or storage areas.
Supplying production lines with heavy or oversized materials.

Key Features:

Capability to lift and transport loads weighing up to several hundred kilograms.
Compliant with international safety standards, such as Machine Directives (ISO 12100, ISO 13849, ISO 3691-4). These systems ensure stable and secure load handling.

uLog LIFT BASE: Flexibility and Adaptability

The uLog Lift Base is the most versatile model in the uLog series. This handling robot’s flexibility makes it ideal for companies with diverse operational requirements.

Key Applications:

Support for custom modules, such as storage racks or handling arms.
Automating internal flows, whether for small items or more complex loads.
Adaptability to evolving environments, such as constantly reorganizing production facilities.

Key Features:

Modular platform allowing multiple configurations thanks to the absence of structural constraints..
Compact dimensions for easy navigation in confined spaces.
Seamless integration with existing management systems.

The uLog series, developed by United Robotics Group, represents a new era of automation. The robot uLog deliver is designed to automate internal deliveries. The uLog lift handles heavy loads, while the uLog lift base, a modular platform, provides flexibility and adaptability. Together, these robots are redefining efficiency standards for industrial handling robots. Their deployment delivers measurable results: increased productivity, fewer errors, and enhanced safety for employees.

United Robotics Group is ready to support businesses through this transformation. Connect with our experts and discover how uLog AMRs can improve your operations and drive profit. For more details about the robots, visit the uLog series overview page.