US-based Kiva Systems has developed a mobile inventory selection system using the latest in Automatically Guided Vehicle (AGV) technology.
The company’s Mobile Fulfilment System (MFS) allows operators to stand still while products come to them.
The system works by storing pallets, cases, and orders on inventory pods that are picked up and moved by a fleet of mobile robotic drive units.
The system is helping provide flexible and efficient order fulfilment, with robotic selection of inventory using an integrated grid pattern and WiFi network.
Kiva Systems Business Development vice-president Rob Stevens spoke to FEN about the breakthrough technology and its range of applications.
How does the system work?
Inventory in a warehouse is stored on our pods, with generally thousands of pods arranged in a grid pattern.
Factory personnel stand around the perimeter of the grid pattern at special workstations.
The sorting system’s control software is integrated with our customer’s inventory systems.
When an order is placed for an item of inventory our software directs a mobile robotic drive unit to retrieve a pod with the items in it, and bring it to a worker at the perimeter of the grid.
This happens continuously, so each worker has a line of robots carrying pods waiting for them.
Every time the worker picks up an item from the drive unit, the pods move on and the next one moves to be picked.
What are the capabilities of the Kiva robot sorting system?
Kiva manufactures two robots. One is capable of lifting 450 kg and the other is capable of lifting 1,300 kg.
Both robots have a set of sensors that allow them to avoid obstacles and navigate using stickers on the floor.
The robots communicate to each other using a WiFi network.
What are the basic components of your robot system?
The basic components of the robot system are the robotic drive unit, storage racks, work station and control software.
How does Kiva ensure accuracy with this system?
We have many methods for ensuring accuracy.
The robot knows it is picking up the right pod because there is a barcode on the bottom of each pod that the robot reads.
The robots navigate using another set of barcodes on the floor, in addition to inertial guidance.
Workers are guided to pick up the right item using a laser pointer and they finally confirm the item by scanning a barcode or reading and RFID tag located on the pod. Our customers tell us that they have dramatically reduced the number of wrong items picked.
What are the advantages of the system?
The system allows much higher productivity, with each worker capable of producing two to three times as many pick ups per hour, since they stay in one place and pick continuously.
The system improves accuracy and can be easily set up or expanded unlike other types of automation which are very complex to install and impossible to expand.
We think of the benefits of the system as speed, flexibility, and ease of use.
What range of applications can this system work best?
Kiva is initially targeting the retail and distribution markets.
These are industries where companies spend enormous resources storing, moving, and sorting items that they pick out and send to stores or customers.
Our approach will also be applicable to the manufacturing space, where companies are combining large numbers of items into assemblies.
How is this system different to other AGVs on the market?
Although technically an AGV, the Kiva system is very different from traditional AGVs, and we do not compete with other AGV companies.
An AGV is typically moved to transport a payload from one point to another in a point-to-point application.
Each AGV in the Kiva system works independently.
The system uses hundreds of robots working together to store, move, and sort thousands of pieces of inventory.
How does this technology necessitate a change in the way companies think about their processes and facilities?
Companies that use the system find they have a lot more flexibility in how they design and operate their distribution centres.
Our customers are just starting to explore how this flexibility creates strategic options for them.
For example, they may choose to build a smaller number of distribution centres, or they might offer same day shipping to all of their customers.
What is the smallest implementation of Kiva Systems that could be cost-effective?
The company generally looks at systems starting at around four workstations and around 30 robots.
At his level the customer has a facility that can make a big difference to their business, and Kiva has the opportunity to recover the cost of integrating and installing the system.
The company’s largest single installation currently has 500 robots operating.
How do you think the market for this technology will change in the near future?
We expect that as the companies see the impact of the speed and flexibility of the Kiva solution, the market will grow.
As it grows there will be different types of applications and robots.
For example, we plan to develop a robot that can operate in a freezer.
Key contact:
Rob Stevens
info@kivasystems.com
www.kivasystems.com
Add a comment