Description

The Skypod is a robot-based, goods-to-person solution that has been developed into a compact, all-in-one system. It offers intermediate order buffering, strict sequencing, and both full-case and each picking – all within a single system without the need for complex subsystems. One could compare it to a “all-in-one kitchenmachine” for warehouses, eliminating the need for additional equipment while incorporating the most important functions into one system.

Within the AS/RS, fulfillment containers are transported entirely by Skypod robots, reducing single points of failure and offering additional capabilities for use, such as:

• Orders (both completed and partially completed) can be natively buffered in the system racks.
• Orders can be sequenced at line level to place items within fulfillment containers in any arrangement.
• Orders can be picked directly to the right-size fulfillment container, avoiding another touch for packing later.
• An infinite number of orders can be opened at once, to maximize the batch factors at the stations, while still picking 1 to 1 with highest efficiency, precision & reaches up to 600 presentations/hour.
• Fulfillment containers can be arranged at outbound for perfect sequencing on trucks or pallets.

Innovations

The main innovation is the integration of various functions into a single system that would normally require adding subsystems like conveyors or sorters to enable them.
Furthermore, the robots are smaller and can travel underneath the rack. This allows more robots to operate within the system, shortens travel times, and increases rack density up to a height of 14 meters.
It offers a 30 % increase in storage density, +50 % in picking efficiencies and can accommodate up to 2.5 x more robots per sqm which leads to a higher performance, more flexibility and will introduce a new standard in the industry.

The Next Generation All-in-One AS/RS offers density that exceeds most cube storage system and throughput that can match shuttle systems.

This all-in-one system seamlessly handles the following functions, requiring no extra hardware:

• Access to all inventory (regardless of pareto) in two minutes or less.
• Handle each picking and full case picking for e-commerce or store replenishment.
• Buffer orders in the inventory racks.
• Sequence orders at the line level and for trucks and pallets.
• Pack orders at the picking station in custom sized packing containers.

Market relevance

The Next Generation AS/RS is the answer to the volatile world of logistics with unstable supply chain processes and unpredictable forecasting.

The target group is companies operating warehouses designed for ecommerce fulfillment and/or store replenishment. Typically, these companies have complex supply chains requiring each and case picking, sophisticated sequencing for packing and shipping, high throughput and tough physical space constraints.

Concerning the market potential, Exotec can currently target the goods-to-person each picking solution market which has an estimated value of 9 billion EUR – with an annual compound growth rate of 15 % (source: Data & market analysis (MS, UBS, Jefferies), Interact analysis).

With the Next Generation, Exotec is expanding its target market to the entire goods-to-person value chain which is currently estimated at 42,3 billion EUR and expected to grow to approximately. 73.6 billion EUR by 2028 (source: Data & market analysis (MS, UBS, Jefferies), Interact analysis).

Customer benefits

Set to officially launch next February, the Next Generation has already been installed, tested, and operationalized in several sites. The advantages are:

1. Reducing investment costs while increasing flexibility by using the same system for different purposes.This eliminates double stocking, additional & unnecessary handling steps.
2. Space & cost savings as space gets optimized by avoiding conveyor lanes, and eliminating the need for specific staging areas.
3. Higher end-to-end customer satisfaction due to efficient order preparation using the native buffer allowing customers to efficiently prepare, store, or retrieve orders in the same system at any time. Due to advanced sorting and sequencing items are picked, packed, and delivered in the optimal sequence to optimize the next stage in the supply chain, such as delivery routes or store replenishment. Customers can prioritize same-day and next day orders, too.
4. Ensuring business continuity. High-availability system thanks to further reduced single point of failure due to simplified bin handling: Robots take over the transportation of all storage and order bins – regardless of whether they are source bins, target bins, cartons, semi-finished or finished orders.
5. Making use of existing facilities. Perfect fit for brown fields due to flexible layout of the system: Adaptable to different storage spaces, ideal for use in existing buildings or different locations.