4 robot management strategies for small warehouse footprints

Power management is a key part of adding mobile robots like this one to warehouses, says Conductix-Wampfler.
Power management is a key part of adding mobile robots to warehouses. Source: Conductix-Wampfler

More than ever, automation technologies are showing up in today’s warehouse and manufacturing facilities, helping to turn over mass amounts of daily orders and support staff while increasing revenue.

In fact, a recent McKinsey & Co. study noted that 70% of survey respondents in the supply chain space plan to invest around $100 million in automation over the next five years. Robotics will play a crucial role in this widening adoption, as shuttle systems, automated guided vehicles (AGVs), autonomous mobile robots (AMRs), and drones become more commonplace, enabling faster and more accurate order fulfillment.

A common misconception in the industry is that these technologies are only suitable for large warehouses, but that is not the case. Although small-footprint warehouses likely require more tailored systems to optimize space while supporting worker safety and productivity, they can also benefit from robotics and automation.

Weaving automation into operations can help smaller warehouses improve efficiency, boost customer satisfaction, and increase throughput and order completion. If you manage a facility with a smaller footprint and are interested in automation, particularly mobile robots, here are key strategies to consider when integrating solutions that can help you make the most of the equipment.

1. Prioritize real-time and secure data collection

    Enhanced connectivity allows for real-time data collection and analysis, enabling better inventory management and operational insights. Particularly important for smaller warehouses, this connectivity will facilitate smarter decision-making, enabling you to respond quickly to changing demands and optimize workflows.

    Upgrading to Wi-Fi 6 is crucial for supporting the increasing number of connected devices in modern warehouses. With faster speeds, improved capacity, and better performance in crowded areas, Wi-Fi 6 offers seamless communication between devices, enhances data transfer, and supports real-time operations monitoring.

    If the data shows that the flow of robots is becoming congested, connectivity and the right fleet management software will enable you to assign them to other areas.

    In addition, be sure to use secure data-transfer systems to safeguard sensitive information and remain compliant with industry regulations. Robust systems provide real-time or near real-time communication between devices, improving operational transparency.

    2. Implement strategic charging in the warehouse

    Flexible charging systems for AGVs and AMRs are important for maximizing the use of the equipment. Advanced technologies such as charging stations and wireless charging systems, can optimize charging cycles to better manage battery health and prolong its life.

    When considering charging for smaller-footprint warehouses, opt for opportunistic charging, in which vehicles recharge during short idle periods rather than going to dedicated stations that require significant space. The benefits of opportunity charging include increased range, flexibility, and reduced downtime.

    Overall, flexible charging solutions paired with opportunity charging can maximize uptime for warehouse operations.


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    3. Enable human-robot collaboration

    Automation can bring a host of benefits to warehouses, but it also introduces new safety concerns. In small warehouses, AGVs, AMRs, and manual and autonomous forklifts will likely share the same space with human workers, which can increase the risk of accidents.

    Ensuring the safety of both workers and automated equipment is crucial for the success of any connected warehouse. When considering mobile robot integration, the equipment should handle repetitive or heavy tasks while allowing human workers to focus on jobs that require judgment or flexibility.

    In addition, consider integrating safety systems into every aspect of the warehouse, from the facility’s layout to robot programming. AMRs of all sizes and payloads should be equipped with sensors and safety protocols that allow for operation around human associates.

    Warehouse operators should also ensure that AGVs/AMRs follow designated routes, maintain clear communication with human operators and other machines, and include emergency shutdown measures.

    4. Scale carefully and dynamically

    If you’re looking to automate warehouse operations, start small and gradually increase capacity as your needs evolve. Small warehouses should benefit from testing smaller-scale solutions before fully committing to an extensive integration of robots, software, and processes.

    Choose systems that can be easily scaled or adapted to accommodate increased inventory or more AGVs or AMRs as demand and throughput grow. Find integrators and vendors that understand your organization’s goals and provides systems that can be customized to meet your needs.

    Choose partners that can grow alongside your business and offer the right equipment when needed. When considering automation, small warehouses will have greater success when collaborating on solutions that maximize space, fully tap into the benefits of automation, and increase overall efficiency.

    Kelly Schroder, Conductix-Wampfler

    About the author

    Kelly Schroder is a business development manager for automated mobile solutions at Conductix-Wampfler, where she is responsible for charging, energy storage and radio solutions within the U.S., Canada, Mexico, Latin America, and Brazil. With more than 15 years of experience, Schroder’s role includes gathering market data, strategic planning, identifying new market opportunities, contributing to product vision, and working to ensure that customer goals are met.

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    Kelly Schroder