Warehouse robotics is in serious growth mode. According to Next Move Strategy Consulting, more than 51,000 autonomous mobile robots (AMRs) were shipped globally in 2023 — a figure projected to hit 180,000 units by 2030.

Warehouse robotics can improve efficiency and performance, especially in the face of labor challenges. There’s a point, however, when just throwing more robots at a problem delivers diminishing returns. It also gets expensive quickly.

But what if modern technology combining advanced cloud and edge computing could optimize AMR deployments, enabling the same results with one-third fewer robots? In this scenario, workflows streamline, asset utilization is increased, capex is reduced, and the bottom line gets a boost. This report will explore five ways to get the most out of every AMR in a warehouse.

1 Enhanced Asset Utilization

Many AMR fleets are much larger than they need to be because of “dwell time” and lack of utilization. This happens in three areas:

1. At induction, when SKUs are put into the automated fulfillment system and a queue of robots often sit idly, waiting for work
2. In aisles, where AMRs park in front of pick locations, waiting for operators to find them
3. At takeoff, where the flow of orders to packout is feast or famine — either far too many robots sit idly, or far too few robots and humans are waiting for work

Utilization can be improved significantly with advanced robotic orchestration that combines intelligent cloud computing with a device-level edge network. This allows the robots to coordinate movements and tasks in real time while the cloud layer continuously analyzes performance data, optimizes workflows and updates schedules. That synchronization ensures robots are efficiently deployed, reducing dwell time while maximizing throughput locally and across facilities. 

2 Greater Cubic Capacity

Tray size has historically limited Amr capacity, forcing extra trips to complete workloads.

Higher-capacity carts enable more efficient picking, a wider range of pickable products and increased batching capabilities. In addition, inexpensive, detachable rolling carts allow robots to handle three times the cubic capacity compared to AMRs with integrated payloads. 

Cart buffering achieves the same throughput with up to 30% fewer robots compared to AMR solutions with integrated payloads. Instead of sitting idly for long periods, robots work continuously, reducing dwell time.

3 Optimized Pick Tours

Advanced orchestration software optimizes workflows by increasing pick density, ensuring a more efficient, streamlined process by pairing multiple robots with a picker. 

Associates connect to the system with lightweight wearable computers and specialized software to provide pickers with real-time guidance and instructions. Meticulously planned routes minimize the distance pickers need to travel while maximizing the number of items collected in each pass. Higher pick density streamlines order fulfillment and enhances throughput while eliminating congestion.

The system assigns pickers to multiple robots, accounting for the locations of pickers, robots, carts and order flow data from the warehouse management system (WMS). Robots are routed ahead of the pickers in a “leapfrog” pattern. As a result, robots don’t sit idly, and the right AMR is always exactly where it’s needed when the picker arrives.

This approach is far more efficient than “swarm” systems, where robots flood the picking area, forcing workers to play “hide and seek” to locate their next AMR and task. Intelligent optimization also increases pick density, allowing more items to be picked in less time. As soon as a picker finishes a task, the next one is strategically placed as close as possible, creating a continuous flow process.

4 Directed Workflows

Most robotic automation systems focus only on the AMRs themselves. Wearable devices can further enhance efficiency and reduce effort by providing workers with precise, directed workflows that span the entire fulfillment process. 

At induction, associates are guided step-by-step as items are introduced into the system, making sure that each item (e.g., carton, tote, bin, box) is properly matched to the right order flow. Robots dynamically align with these induction points, eliminating delays and allowing carts to move into circulation without bottlenecks. 

Wearable computers ensure that pickers always know their next tasks and locations. They’re guided along optimized pick paths that reduce physical strain by minimizing unnecessary movements. This enhances worker satisfaction while reducing the risks of fatigue and related injuries. Ring scanners improve speed and accuracy while leaving both hands free.

During takeoff, the same orchestration ensures completed carts are directed to the correct staging or shipping area. Associates receive clear instructions on where to drop items, while robots disengage and immediately rejoin the pool of available assets. 

The result is a seamless, uninterrupted flow in which every action is guided by real-time system intelligence. By standardizing processes across each stage, directed workflows reduce errors, maximize robotic utilization, and create predictable, efficient fulfillment that scales with demand.

5 Real-Time Visibility

The same wearables that guide workers empower operations leaders with real-time visibility into both workers and robots. This helps drive informed decision-making and proactive management while allowing resources to be reallocated at a moment’s notice.

For instance, third-party logistics (3PL) managers can track rates by picker and client, both currently and historically. Maybe a picker is performing below average, so training is called for. A client with significantly lower cycle times might highlight the need for re-slotting. 

Advanced analytics can analyze 500 to 1,000 data points per order via the system’s telemetry, enabling managers to determine why things went right (or wrong). Wearables and integrated technologies allow minute-by-minute optimization of all key resources — not just AMRs — ensuring that human workers are as empowered and efficient as the robotic systems.

These insights can help 3PLs identify which clients are profitable or unprofitable, allowing them to readjust pricing accordingly.

About Zebra Technologies

Zebra Technologies has long been known for solutions that connect people, assets and data across supply chains. With the introduction of Zebra Symmetry Fulfillment, the company extends its leadership by combining AMRs, cloud intelligence and edge computing in a single orchestration platform. The result is a fulfillment system that scales easily, reduces costs and radically improves efficiency — turning robotic innovation into measurable business outcomes.

Zebra’s portfolio spans hardware, software, services and analytics. It’s best known for its barcode printers, scanners, RFID readers and mobile computing devices, delivering advanced identification and data capture. Zebra also provides rugged tablets, wearables and handhelds that enhance worker productivity in demanding environments.

Beyond devices, Zebra offers workflow optimization through cloud-based platforms, intelligent automation and AI-powered data insights that drive its advanced robotic fulfillment solutions. Zebra software integrates with warehouse management and enterprise systems (WMS, ERP, etc.), enabling visibility and orchestration across supply chains. Zebra Symmetry Fulfillment enhances fulfillment operations by synchronizing human and robotic workflows, increasing productivity by significantly reducing dwell time.

Zebra also leads in real-time location systems and intelligent edge solutions that drive operational efficiency and customer satisfaction. Based in Lincolnshire, Ill., Zebra counts 80% of the Fortune 500 as customers.

Resource link: https://www.zebra.com/us/en/products/autonomous-mobile-robots/order-fulfillment-solutions.html