MHI Solutions Improving Supply Chain Performance
Humanoid robots are poised to gain traction in warehousing and manufacturing.
Agility Robotics’ Digit pictured at work at an Amazon warehouse where it is being piloted to help employees with tote recycling.
The first humanoid robots for manufacturing plants and warehouses were “expensive,” “cumbersome,” “clunky” and “slow,” but newer versions promise to be much more versatile and effective, driving stronger adoption in the coming years, according to Dwight Klappich, vice president of research at Gartner.
Klappich, a fellow with the Gartner supply chain practice, said that by 2027, next‑generation humanoid working robots will account for 10% of new intralogistics smart robots sold globally.
Unlike most robots and cobots, which specialize in performing a single repetitive task, new humanoid robots tied into warehouse management and execution systems will be capable of performing multiple tasks, boosting productivity in short‑staffed factories and warehouses, Klappich said.
“The second generation of humanoid robots addresses many of the physical limitations of the first robots, and they have a fair amount of flexibility in the way they move,” he said. “There are six to 10 vendors that have viable use cases, but adoption has been fairly slow because companies are figuring out where they could use them and what the value proposition would be of substituting robots for human labor.”
Amid rising labor costs, high turnover and a shallow pool of jobseekers, humanoid robots are becoming more competitive from a cost standpoint, Klappich said. Unlike equipment that must be bolted to the floor, robots can move from receiving to shipping according to operational needs, and companies can add or subtract robots based on peak seasons and market dynamics.
Those two forms of flexibility make humanoid robots attractive to manufacturers and distributors that must consider what their businesses will look like in 10 to 15 years when planning major capital expenses and facility upgrades, Klappich said.
“I think that’s why companies will be willing to use humanoid robots even if the technology isn’t necessarily perfect,” he said. “The robots don’t have to do everything a human can do. They can focus on what they can do, and humans will be there for the exceptions. Humanoid robots won’t replace humans entirely, but that flexibility, adaptability and scalability are key reasons why companies are so interested in this.”
Even the newest humanoid robots lack the manual dexterity to pick small e‑commerce items and pack complex orders, but by complementing humans, they could increase throughput significantly.
Klappich pointed to a manufacturer of metal washers measuring one to three inches in diameter. Since the washers have an anticorrosive coating, they often stick together in stacks, and it takes the manual dexterity of humans to twist them apart. Picking robots that use vacuum suction to grab items simply can’t perform that task, and today’s humanoid robots lack that level of manual precision.
Vendors have been working on improving robots’ dexterity for years, with limited success, Klappich said. But early use cases have humanoid robots performing simple tasks such as picking up cases of product, carrying them several steps and placing them on a conveyor belt. Similarly, robots can palletize cases, using artificial intelligence to determine the best way to stack boxes of varying sizes.
Robots can work multiple shifts before charging overnight, making each robot the equivalent of two full‑time workers. The first humanoid robots typically moved slowly, partially out of concern for worker safety, but as people become accustomed to working with sophisticated robots, they’ll no longer have to be “throttled down,” leading to enhanced productivity, Klappich said.
Next‑generation humanoid robots will take their cues not only from a warehouse management system (WMS) or warehouse execution system (WES) but from the verbal instructions of warehouse managers and workers, Klappich said. Using AI, robots will be able to speak with humans, verbally confirming that tasks have been completed and asking for help when they’ve dropped a product or when inventory isn’t where it should be, for instance.
“I think there are some use cases on the near‑term horizon that would have very high value propositions,” Klappich said. “Right now, there are tens of thousands of workers walking through warehouse aisles picking cases, and those can be hard jobs with high turnover. Humanoid robots could cut down on a lot of that wear and tear on people.”
Startups Coming to Market
For a glimpse of what’s possible, look to robotics startup Apptronik that made headlines in August by unveiling its newest robot. At 5‑foot‑8 and 160 pounds, the Apollo model is the first commercial humanoid robot designed for “friendly interaction, mass manufacturability, high payloads and safety,” according to Apptronik.
Apollo will operate in warehouses and manufacturing plants initially before branching out to construction, oil and gas, electronics production, retail, home delivery, elder care and more, Apptronik said. The robot can carry a payload of 55 pounds and runs for four hours before users must swap out its depleted battery for a charged one. It also can be tethered to a charging station for continuous operation.
Jeff Cardenas, chief executive of Apptronik, said Apollo is “a symbol of a future where human potential is augmented by robotics,” improving productivity and worker satisfaction. In March, the company announced an agreement with Mercedes‑Benz to introduce Apollo robots into the automaker’s factories, where they’ll bring parts to the production line for workers to assemble, inspect components and deliver totes of kitted parts later in the manufacturing process.
“As labor challenges and employment trends continue to impact our economy, we need to fundamentally change the way we think about work, particularly in the warehouse and the supply chain,” Cardenas said. “People don’t want to do robotic, physically demanding work in tough conditions, and they shouldn’t have to. Humanoid robots are not just an answer to this challenge; they are a necessity.”
Apollo is powered by linear actuators that mimic the mechanics of human muscles and provide a full range of mobility. The robot has a digital display screen on its chest and LED lights in its head and mouth to communicate its status to users, including battery life, maintenance requirements, the task it’s currently working on and what it will do next.
As a safety precaution, Apollo immediately pauses its movement whenever moving objects are detected within reach. Apollo’s software suite enables point‑and‑click control of the robots, which are capable of unloading trailers, picking cases and palletization.
“Our mission is to build versatile robots that can do work in real‑world applications, from large, powerful movements like transporting boxes and totes to small, precise ones like picking individual items or scanning barcodes,” Cardenas said. By assigning the most tedious workplace tasks to Apollo, companies can “create an even safer, more engaging workplace for employees,” he added.
In June, Apptronik announced a partnership with GXO Logistics Inc. to refine Apollo’s capabilities. The companies pledged to evaluate Apollo’s performance in a lab setting and finetune its AI model before deploying the robot to a U.S. distribution center once ready. Apptronik plans to be in full‑scale production of Apollo robots by the end of this year.
“Apollo has great potential to add value throughout the distribution center, including the most labor‑intensive operational processes,” said Adrian Stoch, chief automation officer at GXO. “These kinds of robotics reduce repetitive work and improve safety while freeing associates to focus on higher‑value‑added activities.”
Prototypes in the Spotlight
Over the past year, GXO has trialed three humanoid robots, including prototypes from Reflex Robotics and MHI member Agility Robotics. In June, Agility’s Digit model became the first humanoid robot deployed in commercial operations when it began working in a GXO warehouse in Flowery Branch, GA. The robot also is being used to move totes at Amazon’s fulfillment center and lab in Sumner, WA.
Digit stands 5‑foot‑9, can carry 35 pounds and understands verbal commands. It’s ideal for warehouse palletization, picking up totes from shelves and other simple tasks.
The company just built a manufacturing plant in Salem, OR that eventually will churn out 10,000 Digit robots annually, with most destined for warehouses and factories.
“We’ve learned so much about how robots can partner with the human workforce and work naturally in human environments, and we can’t wait to see the positive impact the new Digit will have,” said Jonathan Hurst, chief technology officer at Agility Robotics. “When people and robots work together in logistics operations, working conditions improve for people, warehouse efficiency improves overall, and the supply chain moves more smoothly.”
Reflex’s robots are being trained to pack beverages, close a box using a tape roller and cut timber to a specified length using a circular saw, among other tasks. Unlike other models, Reflex’s robots use a wheel‑mounted base instead of walking around on two legs.
Other companies developing humanoid robots include Sanctuary AI, Tesla, MHI member Locus Robotics and MHI member Boston Dynamics. According to Goldman Sachs, the total addressable market for humanoid robots is projected to reach $38 billion by 2035, with 1.4 million units expected to be deployed by then, fueling optimism among startups and their investors.
Sanctuary AI launched the newest generation of its humanoid robot, Phoenix, in April. Phoenix stands 5‑foot‑7, weighs 155 pounds, can carry 55 pounds and walks at a maximum speed of 3 mph.
An older version of Phoenix had a wheel‑mounted base and was piloted in Canadian Tire Corp.’s facilities, where it picked and packed merchandise. Sanctuary AI is partnering with the automotive manufacturer Magna International to build its robots at scale.