Robotics enabled next gen retail supply chain, grey orange

greyorange.comCopyright © 2016 GreyOrange
Robotics Enabled Next-Gen Retail
Supply Chain
Retail Leadership Summit | Feb 15, 2017 | Mumbai
Vaidya Subramanian S
Product Management and Strategy

About GreyOrange
GreyOrange designs, manufactures and deploys advanced robotic systems for automation at warehouses, fulfillment
and distribution centers. Combining robotic expertise and software engineering, GreyOrange helps businesses around
the world solve operational inefficiencies and optimize supply chain.
2011
Foundation Year
650+
Employees
300%
Year-on-year
Revenue Growth
25%
of Revenue in
R&D Investments
8
Patents Filed
35%
Workforce in
R&D

About GreyOrange
CURRENT OFFICES INSTALLATIONS PLANNED OFFICES
NEW DELHI
GURGAON
DUBAI
MUMBAI
KOLKATA
HYDERABAD
BANGALORE
HONG KONG
SINGAPORE
JAPAN
Technology Pioneer
Building Artificial Intelligence In Our Robots
In-house Capabilities
Mechanical | Electronics | Embedded | Software
Leaders In Robotics
End-to-end product conceptualization,
development, installation and support
Business Collaboration
GERMANY

• Challenges in Retail Supply Chain
• How can Automation Help?
Agenda

Source: GreyOrange Study
High Number of Touchpoints
Fragmented Supply Chain
Unfavorable Regulatory Environment
Shortage of Skilled Manpower
SKU Volume and Variability
60%
80%
80%
90%
90%
Challenges in Retail Supply Chain
As a key component, high productivity Warehouses can optimize the entire supply chain
Up to 25% of your overall logistics cost can be for Warehousing

Multiple SKUs in a case
Sortation as per SKU before put away
Needs more manpower at inbound
Operation is prone to errors
High processing time – crunch at peaks
Case 1: Inbound – Complexities in Putaway
Warehouse Size 100,000 sq.ft.
Inbound Throughput Over 50,000 units per day

Automated sortation at the Inbound
Dynamically handle SKU profiles from different vendors
Capture the weight and volume of the units
Automate unit counting process
Case 1: Sortation Solution

Case 2: Push/Pull Demand in Supply Chain

Case 2: Complexities in Push/Pull Demand Model
Fragmentation of inventory along the supply chain
Increased touch points on finished goods
Lesser control over inventory in central warehouse
(inventory pushed to JITs)
Dedicated temperature controlled areas in multiple
places (increased operational cost)

Use of a goods-to-person system to automate the warehouse
handling process in the centralized warehouse
Centralized warehouse to segregate orders retailer-wise and then, ship
orders directly to the distributors
Distributor depots/JITs will only serve as cross-dock warehouses
and will not hold any inventory
Case 2: Goods-To-Person Solution to Push/Pull
Demand Model

Packaging DispatchReceiving SortingPicking and
Combining
StoragePut-awayQuality
Assurance
Inbound Outbound
PROFILER
• Verifying
• Counting
• Dimensioning
• Weighing
• Image Archiving
Simplify storage and retrieval processes Reduce time to get orders to their destination.1 2
Inventory Management
BUTLER
• Scanning
• Put-away
BUTLER
• Inventory
Replenishment
BUTLER
• Scanning
• Picking
• Combining
SORTER
• Image Archiving
• Sorting
• Dimensioning
• Weighing
• Manifest
Robotic Disruption In Warehouse Processes

GreyOrange Butler
A robotic goods-to-person system for automated inventory put-away and order picking in fulfillment and
distribution centers.
Order Picking:
Up to 600 picks/hour*
Fulfillment Accuracy:
99.99%
On-demand
scalability (throughput or storage)
Minimal downtime
with built-in redundancy
Seamless integration
with any WMS and ERP
Powered by artificial
intelligence
Designed for Safety:
7 Levels
Payload:
500 kgs
*per PPS station

A pneumatic-arm based primary sorting conveyor for order profiling,
routing and consolidation in fulfillment and distribution centres.
1D and 2D
barcode scanning
Dimensioning
and weighing system
Pick-Put-To-Light
(PPTL) and bagging stations for
sub-sorting
Configurations:
1500, 3000, 6000 sorts/hour
Sortation Success Rate:
99%
Weight:
Up to 15 kgs
Delivery Time:
< 3 months
GreyOrange Linear Sorter

A loop conveyor system well-suited for operations in
areas with limited space or challenging layouts and high
number of end-destination sorts.
Automated load
management based on dynamic
sorting logic
1D and 2D
barcode scanning
Dimensioning
and weighing system
Configurations:
12000, 15000, 18000
sorts/hour
Sortation Success Rate:
99%
Weight:
Up to 15 kgs
Delivery Time:
< 6 months
GreyOrange Cross-Belt Sorter

Image capturing
to reduce pilferage
High-speed automated
1D and 2D barcode scanning
Real-time capturing of
dimension and weight
Configurations:
1500, 3000, 6000
items/hour
Profiling Success Rate:
99%
Weight:
Up to 15 kgs
Minimum Packet Height:
50 mm
A system for scanning, dimensioning and weighing items
in fulfillment and distribution centres.
GreyOrange Profiler

Please read the whitepaper, “Redefine Retail Warehousing with Automation”.
http://www.greyorange.com/retailsupplychain-whitepaper
Published in 2016 in association with RAI.
CONNECT WITH US AT :
sales@GreyOrange.com
To understand what automation can do for your
business, talk to us.

Why Warehouse Automation?
As a key component, high productivity Warehouses can optimize the entire supply chain
Up to 25% of your overall logistics cost can be for Warehousing
Accelerate order
fulfillment time
Reduce process
complexity
Improve
productivity
Low operational cost Real-time
inventory audit
Reduce error rate
and returns
Minimal
downtime
Improve agility
and scalability
Low
pilferage

High variation in throughput
Visibility and traceability of inventory
High dependency on skilled manpower
Human-intensive audit process
Space optimization (storage density)
Case 2: Outbound – Complexities in Picking
Warehouse Size 12,000 sq.ft.
Outbound Throughput Over 4,000 units per day
SKUs 10,000+

Enable unit picking through Good-to-Person Solution
Based on Pick List, the robot brings the rack with item to the picker
Picker picks the item and keep it in pick-put station
Order consolidation happens at Pick-Put station
Case 2: Goods-To-Person Solution

Case 1: Goods to Person Scenario
Pre-Automation
• Manual search for all materials in picklist for
consolidation at packing station
• Manual intervention leading to multiple
errors
• Order fulfilment within a limited timeframe is
always a challenge
• FMFO violation
• Perpetual inventory count done every day
Automation Solution
Helping a retailer with a large number of SKU’s with unit level orders manage their current warehousing profile and
design for the future.
• Configurable pick-put stations and higher order picking rate in
managing higher throughput
• Increased Storage space utilization & Improve Manpower
productivity
• Reduce pilferage and stock losses with on-demand inventory
audit through the put to light stations; no additional resources
required
• Gain complete visibility of inventory within the warehouse
• Modular MSUs configuration to handle a variety of SKU types
• Scalable and flexible solution to increase storage or throughput
dynamically to handle projected growths
• Visual-aided picking for a dumb proof process, resulting in
reduction in picking errors

Case 2: Sortation Scenario
Pre-Automation Automation Solution
•Sortation of the inbound and outbound system can be handled by
primary and secondary sortation reducing manpower and time taken for
the sortation process
INBOUND
•Since SKU profiles will change with inbounds received from different
vendors, the system can be designed to be dynamic ensuring the same
system can handle a large number of SKUs
•The system can also capture the weight and volume of the units handled
which can later be used to ensure order is correctly picked for dispatch to
stores or end-customers
•The system can handle the unit counting process which can be used to
confirm the units received from the vendor so that the invoice can be
confirmed accordingly
OUTBOUND
•SKUs are picked by batch, fed in the sorter and consolidated as per
orders. The system captures the weight and volume of the units handled
aids in manifest printing while dispacthing to the end customers.
Helping a retailer with a large number of mixed SKU sortation
Each case received from a vendor can contain
multiple SKU’s :
· All units in a case have to be counted
individually and sorted as per SKU
· Only after all the units have been sorted based
on SKU can they be put away in the storage area
· This process typically requires a large number of
manpower to sort the inbound shipment as per SKUs
· Due to the large numbers of units being handled
daily this operation is prone to a errors
· Time taken for segregation can be large
stretching the time taken for warehouse operation
and this gets amplified during the peaks

Case 3: PPTL & GSTAT Scenario
Pre-Automation
• Human intervention was
leading to growing errors
• Issues with scalability as the
business grows
• Managing cut-off time with
manual sortation is extremely
challenging
• Inaccurate Weighing and
Dimensioning of irregular
shaped shipments leading to
revenue loss
Automation Solution
GreyOrange G-Stat and Sub-Sorting: Static
Dimensioning, Weighing and Barcode Scanning System
integrated with PPTLs assists in sortation of the
shipments (Pick – Put – to – Light)
Operator scans shipment and places on G-Stat | All item
information is captured in the system | When items are
scanned for sorting, the logic mapped PPTL glows making
the process efficient and fast.
GreyOrange Difference
• Achieved Avg Throughput of 350 items
per hour per station
• Profiling and weighing of shipments with
99.9% accuracy
• Profiling of both regular and Irregular
shaped shipments
• Accurate, error free Sortation
• Easy integration with existing systems
with simple dashboards

Robotics enabled next gen retail supply chain, grey orange

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