The Challenge
DHL Supply Chain was using a manual cart-based picking system that created the need for associates to walk long distances, which resulted in fatigue at the end of the day. Along with the physical strain on associates, DHL also had to sort out inaccuracies resulting from tired associates that made mistakes. DHL looked to other warehouse operation solutions to reduce quality issues and streamline cycle times. The distribution manager shared that quality was the first driver for the solutions they considered, emphasizing the primary focus of DHL’s improvements.
The Solution
DHL Supply Chain improved their healthcare warehouse operations by deploying 100 Locus Robots and implementing a "pick-to-box" approach. With this warehouse automation solution, DHL significantly reduced quality issues by 50%, with fewer customer complaints.
The Results
DHL’s deployment of 100 autonomous mobile robots (AMRs) from Locus Robotics resulted in several benefits across multiple operational areas:
- Enhanced Order Accuracy: By implementing a “pick-to-box” approach, DHL significantly reduced quality issues by 50%, with fewer customer complaints.
- Cycle Time Reduction: DHL’s cycle time for orders decreased by 60%.
- Improved Efficiency: The elimination of a separate packing area streamlined operations and freed up resources, allowing DHL to fulfill orders directly in their shipping boxes.
- Reduced Associate Strain: By replacing carts with AMRs, DHL saw increased consistency in warehouse associate output, as the physical demands of walking long distances with heavy loads were minimized.
