Case Study

In 2014, Verity set out to tackle the challenges of automating inventory management in highly dynamic warehouse environments. The mission was to create a solution capable of delivering real-time insights, improving accuracy, and enhancing operational efficiency without disrupting human workflows. A key challenge in enabling safe and continuous operation of autonomous drones in environments where humans and robots must coexist – a critical requirement for facilities with 24/7 operations and limited downtime.

Collaboration Mode, a breakthrough designed to address this challenge, was co-developed with a key client, Ingka Group, IKEA largest franchisee of the IKEA brand, whose Distribution Center played a central role in the development process. This partnership allowed Verity to refine the system to meet real-world warehouse demands and ensure both high value and unmatched reliability in collaborative environments.

Traditional inventory management methods generate inefficiencies, including pallet hunting, write-offs, oversells, and split deliveries, which undermine accuracy and customer trust. Repetitive, manual barcode scanning is also time-consuming and physically taxing. To address these issues, warehouse operators – retailers, manufacturers, third-party logistics providers, and food and beverage distributors – needed a solution that not only automates inventory scanning but vastly increases how much and how frequent scanning can be performed, while also improving safety, reducing operational downtime to increase productivity, and eliminating errors, all while fitting seamlessly into the operational flow of busy warehouses.

In 2020, Verity delivered its first autonomous inventory system powered by self-flying drones and designed to operate in the absence of personnel and in complete darkness. Building on this success, Verity piloted Collaboration Mode from 2023 to 2024 at a client site, adhering to one of our core principles: developing solutions in partnership with clients to ensure the system delivers both high value and the highest reliability. This rigorous co-development process culminated in the introduction of Collaboration Mode as a core functionality in early 2024. This advancement enables the data collection missions to be executed safely and continuously alongside human workers, forklifts, and other warehouse equipment. Critical for expanding automation to facilities with little or no non-operational hours, collaboration enables 24/7 inventory tracking without human intervention.

Operating inventory drones safely and continuously when warehouse staff are present is achieved via the Verity dashboard where users assign specific zones to be scanned during operating hours. Data collection missions are pre-scheduled and utilize a custom indoor positioning system to navigate higher levels of storage. Once assigned and activated, Verity work zones are established and aligned with operations in the warehouse, with specific aisles or areas dedicated to Verity operations. The entire process is zero-touch, requiring no human interaction.

In Collaboration Mode, customers have the flexibility to determine their preferred level of collaboration between drones and staff. For instance, at its pilot Distribution Center, Ingka has opted for no aisle blocking, segregating data collection work to higher levels (levels 3 and up) while reserving the picking level below for human activity. Other clients may choose alternative segregation strategies, such as dedicating entire aisles to Verity operations. In both approaches, the Verity drones seamlessly transition through pre-determined transition zones – flying high overhead and away from other activities – and execute missions within their designated work zones without disrupting operations in other areas of the warehouse.
With a simple toggle of a switch on the Verity dashboard, users can assign and activate additional Verity work zones whenever new inventory counts are desired. To further streamline operations and minimize human interactions, the system can automatically align Verity work zones with WMS operations through the Verity API.

Verity’s collaboration functionality is powered by multi-sensor collision avoidance systems. The system’s integration with existing warehouse systems optimizes mission plans to minimize interactions between drones, workers, and equipment. This innovation addresses a key barrier to adoption, enabling the system to integrate seamlessly into high-traffic environments while delivering real-time inventory data that mirrors physical inventory. To mitigate potential risks associated with system and human interaction, Verity implements additional safety protocols when in collaboration mode:

• Optimized Navigation: Drones utilize forward-facing navigation and reduced speed to enhance obstacle detection capabilities.
• Streamlined Obstacle Handling: Drones attempt minimal rerouting when encountering obstacles, prioritizing safe navigation.
• Safety Landing Protocols: Drones execute safety landings with increased visibility to minimize emergency risks.

For Ingka, Collaboration Mode brings an even greater level of improved efficiency to warehouse operations while reducing the facility downtime required for tasks such as cycle counting. It also offers significant benefits to worker safety and satisfaction. By removing the need for repetitive, physically demanding tasks, the system allows employees to focus on higher-value activities while reducing risks – including manually scanning inventory at heights – and improving overall workflow efficiency.

As Ingka shared on its website on August 16, 2024, the implementation of 24/7 operational drones is transforming the inventory management, significantly boosting operational efficiency whilst also enhancing co-worker productivity. The new system enables simultaneous inventory checks, eliminating the need to block aisles and disrupt workflows. Co-workers can take immediate actions based on real-time data from the drones, significantly increasing product accuracy, and decreasing their workload.

Tommy Niemierowski, Fulfilment Project Implementation Manager at Ingka, explains: “Implementing a solution that truly makes a difference in our warehouses is an immensely rewarding experience. The installation process itself is relatively straightforward, and the reward is monumental, as it facilitates collaboration amongst various stakeholders.” Integrating 24/7 operational drones into the retailers warehouses is not only a great step in inventory management but also a boost for employee well-being. By taking over the physically strenuous task of inventory checks, these drones reduce the ergonomic strain on co-workers, allowing them to focus on lighter and more interesting tasks.

Sustainability has been another key value of the solution. The Verity system contributes to reductions in inventory-related emissions, improves energy efficiency, and aligns with five common Sustainable Development Goals (SDGs). These sustainability benefits not only enhance environmental performance but also support each company’s broader commitment to responsible business practices.
The introduction of Collaboration Mode in 2024 was a pivotal milestone, enabling Verity’s technology to overcome barriers to adoption and deliver a truly transformative solution. Verity’s Collaboration Mode revolutionizes warehouse operations by enabling the system to seamlessly integrate with existing activities. Collaboration Mode ensures efficient inventory management while prioritizing personnel safety through meticulous space separation mechanisms and stringent safety measures. By integrating advanced robotics into high-stakes environments where humans and machines work side-by-side, Verity has established a new benchmark for inventory management, empowering clients that operate warehouse 24/7 with unparalleled accuracy, sustainability, and operational excellence.

Key Figures and Data:

• Release date: Collaboration Mode launched in August 2024.
• Key benefit: Enables 24/7 system operation in facilities with limited downtime.
• Labor optimization: Reduces manual work by 80 % while performing 20x more inventory checks.
• Workforce safety: Eliminates repetitive, physically demanding tasks and improves safety and job satisfaction.
• Cost savings: Generates 800,000 labor hours labor saved annually across 100+ client sites.
• Operational improvements: Prevents 6,200 operational issues per site annually.

Environmental impact:

• Reduces inventory-related CO₂ emissions by 25 % (20 – 30 k full pallet locations); equivalent to 800 – 1,000 t CO2 annually.
• Cuts energy consumption by up to 30x compared to traditional systems/methods.

Sustainability contributions:

• Aligns with the six Sustainable Development Goals (SDGs) including safety, education, decent work & economic growth, industry & innovation, and climate action.
• 200 installations could contribute ~20 % toward global emissions reduction goal.