robotics enabled next gen retail supply chain, grey orange

greyorange.comCopyright © 2016 GreyOrange

Robotics Enabled Next-Gen Retail

Supply Chain


Retail Leadership Summit | Feb 15, 2017 | Mumbai

Vaidya Subramanian SProduct Management and Strategy


About GreyOrange

GreyOrange designs, manufactures and deploys advanced robotic systems for automation at warehouses, fulfillment

and distribution centers. Combining robotic expertise and software engineering, GreyOrange helps businesses around

the world solve operational inefficiencies and optimize supply chain.

2011Foundation Year

650+Employees

300%Year-on-year Revenue Growth

25%of Revenue inR&D Investments

8Patents Filed

35%Workforce in

R&D


About GreyOrange

CURRENT OFFICES INSTALLATIONS PLANNED OFFICES

NEW DELHI

GURGAON

DUBAIMUMBAI

KOLKATA

HYDERABAD

BANGALORE

HONG KONG

SINGAPORE

JAPAN

Technology PioneerBuilding Artificial Intelligence In Our Robots

In-house Capabilities

Mechanical | Electronics | Embedded | Software

Leaders In RoboticsEnd-to-end product conceptualization,

development, installation and support

Business Collaboration

GERMANY


• Challenges in Retail Supply Chain

• How can Automation Help?

Agenda


Source: GreyOrange Study

High Number of Touchpoints

Fragmented Supply Chain

Unfavorable Regulatory Environment

Shortage of Skilled Manpower

SKU Volume and Variability

60%

80%

80%

90%

90%

Challenges in Retail Supply Chain

As a key component, high productivity Warehouses can optimize the entire supply chain

Up to 25% of your overall logistics cost can be for Warehousing


Multiple SKUs in a case

Sortation as per SKU before put away

Needs more manpower at inbound

Operation is prone to errors

High processing time – crunch at peaks

Case 1: Inbound – Complexities in Putaway

Warehouse Size 100,000 sq.ft.

Inbound Throughput Over 50,000 units per day


Automated sortation at the Inbound

Dynamically handle SKU profiles from different vendors

Capture the weight and volume of the units

Automate unit counting process

Case 1: Sortation Solution


Case 2: Push/Pull Demand in Supply Chain


Case 2: Complexities in Push/Pull Demand Model

Fragmentation of inventory along the supply chain

Increased touch points on finished goods

Lesser control over inventory in central warehouse

(inventory pushed to JITs)

Dedicated temperature controlled areas in multiple

places (increased operational cost)


Case 2: Push/Pull Demand in Supply Chain


Use of a goods-to-person system to automate the warehouse

handling process in the centralized warehouse

Centralized warehouse to segregate orders retailer-wise and then, ship

orders directly to the distributors

Distributor depots/JITs will only serve as cross-dock warehouses

and will not hold any inventory

Case 2: Goods-To-Person Solution to Push/Pull

Demand Model


Packaging DispatchReceiving SortingPicking andCombining

StoragePut-awayQualityAssurance

Inbound Outbound

PROFILER

• Verifying• Counting• Dimensioning• Weighing• Image Archiving

Simplify storage and retrieval processes Reduce time to get orders to their destination.1 2

Inventory Management

BUTLER

• Scanning• Put-away

BUTLER

• InventoryReplenishment

BUTLER

• Scanning • Picking • Combining

SORTER

• Image Archiving• Sorting• Dimensioning• Weighing• Manifest

Robotic Disruption In Warehouse Processes


GreyOrange Butler

A robotic goods-to-person system for automated inventory put-away and order picking in fulfillment and distribution centers.

Order Picking:

Up to 600 picks/hour*

Fulfillment Accuracy:

99.99%

On-demand scalability (throughput or storage)

Minimal downtime with built-in redundancy

Seamless integrationwith any WMS and ERP

Powered by artificial

intelligence

Designed for Safety:

7 Levels

Payload:

500 kgs

*per PPS station


A pneumatic-arm based primary sorting conveyor for order profiling, routing and consolidation in fulfillment and distribution centres.


1D and 2Dbarcode scanning

Dimensioningand weighing system

Pick-Put-To-Light(PPTL) and bagging stations for

sub-sorting

Configurations:

1500, 3000, 6000 sorts/hour

Sortation Success Rate:

99%

Weight:

Up to 15 kgs

Delivery Time:

< 3 months

GreyOrange Linear Sorter


A loop conveyor system well-suited for operations in areas with limited space or challenging layouts and high number of end-destination sorts.

Automated load

management based on dynamic

sorting logic

1D and 2Dbarcode scanning

Dimensioningand weighing system

Configurations:

12000, 15000, 18000 sorts/hour

Sortation Success Rate:

99%

Weight:

Up to 15 kgs

Delivery Time:

< 6 months


GreyOrange Cross-Belt Sorter


Image capturingto reduce pilferage

High-speed automated

1D and 2D barcode scanning

Real-time capturing of dimension and weight

Configurations:

1500, 3000, 6000 items/hour

Profiling Success Rate:

99%

Weight:

Up to 15 kgs

Minimum Packet Height:

50 mm


A system for scanning, dimensioning and weighing items

in fulfillment and distribution centres.

GreyOrange Profiler


Please read the whitepaper, “Redefine Retail Warehousing with Automation”.

http://www.greyorange.com/retailsupplychain-whitepaper

Published in 2016 in association with RAI.

CONNECT WITH US AT :

[email protected]

To understand what automation can do for your

business, talk to us.

http://www.greyorange.com/retailsupplychain-whitepaper


Why Warehouse Automation?

As a key component, high productivity Warehouses can optimize the entire supply chain

Up to 25% of your overall logistics cost can be for Warehousing

Accelerate order fulfillment time

Reduce process complexity

Improve productivity

Low operational cost Real-time inventory audit

Reduce error rate and returns

Minimal downtime

Improve agility and scalability

Low pilferage


High variation in throughput

Visibility and traceability of inventory

High dependency on skilled manpower

Human-intensive audit process

Space optimization (storage density)

Case 2: Outbound – Complexities in Picking

Warehouse Size 12,000 sq.ft.

Outbound Throughput Over 4,000 units per day

SKUs 10,000+


Enable unit picking through Good-to-Person Solution

Based on Pick List, the robot brings the rack with item to the picker

Picker picks the item and keep it in pick-put station

Order consolidation happens at Pick-Put station

Case 2: Goods-To-Person Solution


Case 1: Goods to Person Scenario

Pre-Automation

• Manual search for all materials in picklist for

consolidation at packing station

• Manual intervention leading to multiple

errors

• Order fulfilment within a limited timeframe is

always a challenge

• FMFO violation

• Perpetual inventory count done every day

Automation Solution

Helping a retailer with a large number of SKU’s with unit level orders manage their current warehousing profile and

design for the future.

• Configurable pick-put stations and higher order picking rate in

managing higher throughput

• Increased Storage space utilization & Improve Manpower

productivity

• Reduce pilferage and stock losses with on-demand inventory

audit through the put to light stations; no additional resources

required

• Gain complete visibility of inventory within the warehouse

• Modular MSUs configuration to handle a variety of SKU types

• Scalable and flexible solution to increase storage or throughput

dynamically to handle projected growths

• Visual-aided picking for a dumb proof process, resulting in

reduction in picking errors


Case 2: Sortation Scenario

Pre-Automation Automation Solution

•Sortation of the inbound and outbound system can be handled by

primary and secondary sortation reducing manpower and time taken for

the sortation process

INBOUND

•Since SKU profiles will change with inbounds received from different

vendors, the system can be designed to be dynamic ensuring the same

system can handle a large number of SKUs

•The system can also capture the weight and volume of the units handled

which can later be used to ensure order is correctly picked for dispatch to

stores or end-customers

•The system can handle the unit counting process which can be used to

confirm the units received from the vendor so that the invoice can be

confirmed accordingly

OUTBOUND

•SKUs are picked by batch, fed in the sorter and consolidated as per

orders. The system captures the weight and volume of the units handled

aids in manifest printing while dispacthing to the end customers.

Helping a retailer with a large number of mixed SKU sortation

Each case received from a vendor can contain

multiple SKU’s :

· All units in a case have to be counted

individually and sorted as per SKU

· Only after all the units have been sorted based

on SKU can they be put away in the storage area

· This process typically requires a large number of

manpower to sort the inbound shipment as per SKUs

· Due to the large numbers of units being handled

daily this operation is prone to a errors

· Time taken for segregation can be large

stretching the time taken for warehouse operation

and this gets amplified during the peaks


Case 3: PPTL & GSTAT Scenario

Pre-Automation

• Human intervention was

leading to growing errors

• Issues with scalability as the

business grows

• Managing cut-off time with

manual sortation is extremely

challenging

• Inaccurate Weighing and

Dimensioning of irregular

shaped shipments leading to

revenue loss

Automation Solution

GreyOrange G-Stat and Sub-Sorting: Static

Dimensioning, Weighing and Barcode Scanning System

integrated with PPTLs assists in sortation of the

shipments (Pick – Put – to – Light)

Operator scans shipment and places on G-Stat | All item

information is captured in the system | When items are

scanned for sorting, the logic mapped PPTL glows making

the process efficient and fast.

GreyOrange Difference

• Achieved Avg Throughput of 350 items

per hour per station

• Profiling and weighing of shipments with

99.9% accuracy

• Profiling of both regular and Irregular

shaped shipments

• Accurate, error free Sortation

• Easy integration with existing systems

with simple dashboards