The guide bellow will help in understanding questions to estimate number of robots needed
1. Type of Robot
2. Total Operational Hours > 10 Hours?
The total operational time is the total time the operation (picking, put-away, inventory, etc.) that the robot could help optimize is continuously running.
For example: Warehouse A & B are looking for to optimize their picking process with a CartConnect.
If warehouse A does picking for 3 shifts/day, 8 hours each (24 hrs/day), then warehouse A has an overall operation time of 24 hours which means the total operational hours are greater than 10 hours.
If warehouse B does 2 shifts/day, 8 hours each, but only inventory and clean up is done in shift #2 (outside of this scope) and picking in shift #1, then warehouse B has an overall operation time of 8, hence it’s less than 10 hours.
Therefore, the total operational time is based on the quantity and duration of shifts needed in whatever operation the robot could improve.
Usually expressed in pallets/hour, totes/hour, LPH, carts/hour, etc – this is to understand how many robots are needed to cover the distance input above.
Do you know how many times products are moved per hour from point A to B?
Example: A forklift driver moves 20 pallets per hour from Zone A to Shipping – this should be the trips per hour
We can also derive it using orders per day.
Example: Company X ships 3000 orders per day.
Their warehouse is operational for 10 hours per day.
Orders/hour = 3000/10 = 300 orders/hour.
How many orders fit on a Fetch cart with a 32 x 32 inch surface area with 3 shelves?
Let’s say 10 orders (or cartons) fit on a Fetch cart. This means the robot needs to move 300/10 = 30 trips/hour to maintain the current operation =>Trips/hour = 30
Roundtrip distance is the distance the workers are currently walking to move product. This should be the distance between pick up and drop-off locations.
Simple Example: If pickers move pick items to a bin that needs to be sent to shipping, the total roundtrip distance would be the distance between Picking and Shipping multiplied by 2
Complex Example: If pickers move pick items to a bin that can be sent to either inspection, receiving, or assembly, you would need to take a weighted average of the different possibilities with their respective distances.
To calculate the weighted average distance traveled, use the trips/hr of each workflow to obtain the weighted % (“= workflow trips/ total trips”) then multiply the respective worflow distance with
the weighted % to obtain the weighted distances. Finally, sum all of the weighted distances and multiply the total by 2 (to get total roundtrip distance)
(Enter 0 if CartConnect 100 or F1500 Cart is selected)
This is the time it takes to load product on to the robot. The dwell time for the robot influences how many robots we need to meet the throughput rate.
Example: The user summons a robot to load it, and they take 5 minutes to load product onto the robot, and another 5 minutes to unload it on the other end.
It takes additional 600 seconds per trip in waiting. This number helps in estimating how many additional robots are needed to complete the required trips/hour.
(Enter 0 if HMI,F500, F1500 or Rollertop is selected)
This is the time it takes to load the cart fully, and unload at the other end.
Example: If order A has 50 items and each item takes 5 seconds to pick from the shelf to cart, the loading time per trip or order is 50 x 5 = 250 seconds per cart.