Successful implementation of first Boston Dynamics robots

Arvato has successfully taken the next step in its automation strategy. As part of the cooperation with Boston Dynamics, a global leader in the development of highly mobile robots, the leading 3PL provider deployed the first two Stretch robots at its logistics campus in Louisville, Kentucky.

Arvato uses Stretch to automatically unload a wide variety of loose-loaded boxes from containers. Automating anything with variability is difficult, so finding a solution that could gently handle the cartons was a real challenge. The implementation marks the next step in Arvato’s Automation Strategy and adds another proven solution for the existing Automation Toolbox, which, when combined with smart data capturing, robotic palletizing and pallet transports by AGVs (automated guided vehicles) and AMRs, (autonomous mobile robots) completes the process chain for a fully automated goods receiving process.

The mobile robots are entirely self-contained, requiring no power or air lines for operation. This mobility significantly reduces infrastructure costs and training time for Arvato’s employees. The system utilizes a vision system to detect the front of all boxes in a container. The robot then makes decisions in real time on which box or boxes to pick and how to do so. The single robotic arm is equipped with a gripper at the end consisting of several rows of suction cups, allowing it to grab boxes from various angles and carefully places the boxes on a conveyor belt that will carry it further into the warehouse.

The implementation gives more consistency and the multipicking feature allows higher throughputs, especially with smaller, lighter cartons. It can also multipick some of the heavier cartons that the manual unloading teams wouldn't be capable of doing. It can handle packages of various sizes weighing up to 23 kilograms (50 lbs), and work continuously for up to 16 hours.

“Seasonal planning is very critical to Arvato operations,” says Rachael Miller, Senior Director of Operations at Arvato’s Louisville campus. “There are often unknowns in the supply chain. With Stretch being very consistent on its unload rate, we can plan additional capacities where we need them. We can also plan for off hours where we may not have a scheduled shift in place, with just one operator putting Stretch into a truck.”

“Stretch creates efficiencies in the warehouse by automating the task of unloading trailers and containers,” says Marc Theermann, Chief Strategy Officer, Boston Dynamics. “Planning and predictability are essential for efficient supply chain operations, and robots like Stretch can help Arvato maintain consistency in their unloading rate while alleviating the physical strain on employees. With Stretch, Arvato can continue its automation journey, reduce costs, and deliver increased efficiencies to its customers.”

“Overall, the perception of Stretch has been very positive,” explains Rachael Miller. “We made it clear from the first day, that Stretch won't replace our workforce, but not only relieves our colleagues in the warehouse of a physically demanding work, but also allows us to upskill them to perform more meaningful warehouse tasks.”

The partnership with Boston Dynamics initially involves the implementation of a total of ten Stretch robots at various Arvato locations. Following the successful launch of the two models in Louisville, the next steps will be to equip additional sites in the US as well as in Europe.