Exotec has introduced a new version of its Skypod robot that not only supports order picking, but can also buffer and sort shipping boxes. Because this robot can drive under racks, unlike its predecessor, the system offers up to 30 per cent more storage density. Productivity at workstations is also up to 50 per cent higher than before thanks to several improvements.
The Next Gen Skypod includes several design improvements, including a more compact Skypod robot and a new workstation. The main improvement is that the new robots not only transport stock bins, but also shipping boxes to the workstation. The order picker can place the correct number of items from the stock bin into the shipping box, after which the robots dispose of both the stock bins and shipping boxes again and store them in the racks.
So the storage system is no longer just used for picking stock, but also for buffering shipping boxes. When the shipping boxes need to be loaded into the truck, the robots bring the shipping boxes to the changer at the right time and in the right order, where the shipping boxes are placed on a conveyor towards the truck at high speed from the robots. By also using the storage system for buffering and 'sequencing' shipping boxes, Exotec says a separate buffering and sorting system has become unnecessary.
Improvements at a glance:
- Integrated buffering: the new Skypod system provides buffering within the system. Completed or partially completed orders are automatically stored on shelves until they are ready for dispatch or further consolidation. This reduces the need for separate picking locations or external buffer systems.
- Perfect sequencing: the system guarantees strict outbound sequencing before orders are prepared. Robots group orders and deliver them in a specific order to the Exchanger, which then sends them to the outbound line. This enables efficient loading of pallets, containers or trucks based on delivery routes, shop shelf plans or other unloading requirements, without the need for external sorting equipment.
- Pick-and-Pack: packing becomes an integrated part of the order picking process. Operators pick directly into shipping containers, eliminating manual packing operations further down the line. This functionality fits perfectly with customised packaging solutions. These solutions can be integrated with the Next-Gen Skypod, allowing products to be picked directly into customised containers, significantly reducing last-mile delivery costs.
"When designing the Next Gen Skypod, our goal was to create a solution that would set the industry standard of operational excellence and elegance for the next decade and beyond," says Romain Moulin, CEO and co-founder of Exotec. "We see our customers transforming their entire supply chain thanks to this innovation, from combining case and item picking to reducing transport costs with outbound sequencing. It's great to see that impact."
Implementation at E.Leclerc
Exotec developed the new generation Skypod in response to changing market needs and feedback from existing customers, who are increasingly deploying warehouse robotics for a wider range of processes. Over the past two years, Exotec has sold and implemented the updated Skypod system in stealth mode worldwide. The company has now completed more than 20 projects worldwide, accounting for a total turnover of USD 400 million. Customers such as clothing company Oxford Industries (Tommy Bahama, Lilly Pulitzer, Southern Tide, etc.), Grainger and supermarket chain E.Leclerc have deployed the solution to optimise and strengthen their supply chain processes.
"We chose Exotec because of its high storage density and operational flexibility. Robotic developments have allowed us to create a larger buffer area to prepare orders within the system," says Maxence Maurice, CEO of E.Leclerc in Seclin. "Previously, the customer journey, from arrival at the collection point to departure with groceries, took between 10 and 15 minutes. Today, with the latest Exotec solution, this takes less than 5 minutes."
