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High Performance Returns Handling Autonomous Mobile Robots and More

by Conveyco Marketing · Published April 19, 2021 · Updated June 7, 2024

Returns handling otherwise known as reverse logistics using high-performance Autonomous Mobile Robots (AMRs) and other technologies.

It is important to understand your data and business case… to create your RightFIT. Touch items once, or as little as possible. Try to put returns directly into active inventory locations for seamless efficiencies. Can you cross dock returns into open orders without losing throughput? To accomplish this, you will need to understand your slow, average, and busy periods. Likewise, project growth and a change of SKUs.

The first step is utilizing a RightFIT methodology. The RightFIT methodology helps you understand your returns, your business, and your future, which is all tied together. This seven-step methodology includes a deep dive data analysis. We analyze the design objectives; we then do an alternative analysis to make sure that we have the best and always apply your business case. This keeps focus on finding the best return on investment, making sure that it aligns, and it is exactly what your organization is looking for. We set a clear path to success, create an execution roadmap. And then of course, a life cycle Nexus, which is how this system is going to run at peak performance for months, years, and decades forward. So that this type of methodology, is important to your overall success.

So, for returns and profitability, some associated costs, returns make up $642.6 billion annually. That is a lot. I am not telling you anything you do not know if it were not impacting you and your organization you would not be here watching this.

The costs become staggering when you consider restocking items, return shipping, the Q&A process, packaging… merchandise that is lost or damaged… the list goes on. These are some of the costs that handling your returns must consider protecting your profitability.

You need to have a plan. Free returns are not free to you they cost real money. Likewise, the functions returns, overstock, obsolescence, and redistributing inventory need to be addressed. There are many facets to returns. And this must be analyzed and planned, which is directed by our RightFIT methodology.

Make returns easy for the customer. Having a plan and capacity for peak and valley returns activity. All too often, systems are designed based on averages. If you design based on averages, your system will fail. So, we need to take in all parts of your business and how your returns activity impacts that. And likewise, other returns going back to DCs stores, third party locations. This is all part of that process of understanding your returns business and processes and designing a solution.

There is a myriad of technologies that are available today in the conveyance, buffering and handling of returns. You have a full range of AMRs, autonomous mobile robots, Horizontal carousels, an oldie but goodie that work great for returns, Conveyor of course, and overhead pouch and pocket sorters plus vertical sequencing modules.

We will go into details in a little bit. Also, many of these systems can integrate with pick to light, pick to voice, augmented vision systems, and put walls. Of course, the glue is often the software and its ability to manage the equipment and orchestrate the facility. This might be done using your existing WMS or a layer of WES software. This is part of the analysis.

Let us take a deeper look into the technologies. So right now, you are looking at a Stacker-Bot AMR. These AMRS use telescopic forks that store and retrieve totes one or two positions deep into the rack. The bots can store and retrieve up to 5 totes at one time reducing travel time. Multiple Stacker-Bots work as a team and go in and out of the rack to deliver the totes to and from receiving, Q&A, order picking and pack out… wherever they are required in the facility.

So, a very efficient, very effective way of handling returns Skypod by Exotec. You have AMRs that climb up and down the rack. They get to their location They pull the tote onto their back, go down, get in the queue at the workstation where the operator makes the picks. I will show you an animation in just a second. This makes the system a bit easier to see. The system is just rack and then you add the Skypod AMRs who do most of the work. Then add workstations which can be as simple or complicated, as needed based upon your throughput, labor, business requirements and goals are. The best part is the flexibility, adding more workstations, adding more AMRs, is all available. The system is very easy to expand and to operate.

A Go-Fer Bot, is an AMR that travels below the racks, lifts the rack it requires, and delivers it to the proper workstation. What makes this system powerful is the fast ROI and flexibility. These racks can be used for any combination of handling loose items, cases, hanging garments, and even pallets, bins or gaylords. Likewise, there are all types of options that can be utilized within the workstation including: pick the light, voice, or augmented vision.

The same system can be used for picking, replenishment and placing returns into active pick locations all simultaneously using the same or dedicated workstation. This eliminates an extra touch or two for higher efficiency.

Next, we have a Pouch or Pocket Sorter. Returned items can be inducted into a pouch. The pouch is then stored and sequenced in an array of overhead conveyor. Every item is stored out of the way. When a specific SKU is required to either do a put away or to complete an order, the Pocket Sorter will deliver the item or items to correct workstation.

The TiltSort Bot runs on a table with totes or gaylords on the perimeter. Induction can be done with operators… robotic arms, or even an A frame for high quantity pieces. Once a piece is inducted on the TiltSort Bots they move immediately to the open order and deposit the inventory into a tote or gaylord.

The TiltSort Bot is also available with a crossbelt top. Items are inducted and the bot deposits the item into the correct tote or gaylord. The totes and gaylords can be manually moved to the next location or an AMR can remove them and deliver them.

The Hi-Tilt Bot. This system utilizes a very simple induction process and uses its crossbelt or tilt tray system to deposit items into bins or gaylords which are located on the perimeter. The beauty of this system is the lack of infrastructure that is required. The gaylords can represent stores, aisles, departments, postal routes and more. An AMR or operator can be used to move the gaylords to its next destination when ready.

A vertical sequencing module or VSM. People confuse this with a vertical lift module or VLM, but it is not. The vertical sequencing module has five independent totes wide in the modules front and back. Imagine returns coming into Q&A. They accept the return, place them into a tote. The totes are automatically routed to the VSM. When an open order requires the SKU, the tote is routed via conveyor or AMR to the workstation. Likewise, when enough pieces of any SKU are in the system they can be sequenced and delivered to a workstation to be consolidated.

The key is understanding your business to determine the RightFIT.