Supply Chain Stories: Autonomous Forklifts in the Warehouse

In the final episode of season two of our “All Business. No Boundaries.” podcast series, we talked to?Brendan Washington, Vice President of Logistics and Customer Supply Chain at Campbell Soup Company,?Jim Gaskell, Director of Global Automation and Emerging Technologies at Crown Equipment, and?Mark Smith, Senior Vice President of Operations at DHL Supply Chain. The group focused on our first North America deployment of autonomous forklifts in the warehouse, discussing this innovative technology and its impact on the operation.

What are autonomous forklifts?

A couple of things may come to mind when you read the words “autonomous forklift.” In its essence, the solution is simply a traditional forklift that operates without a human driver. The installation features Crown R 1000 Series DualMode reach trucks fitted with JBT Automated Systems robotics technology that perform traditionally manual tasks 24/7 with minimal supervision required. Fully integrated into the Warehouse Management System (WMS), the autonomous forklifts can completely replace a manual vehicle. They can put away a 400-inch pallet in an 11-foot aisle, which translates to seven levels in a racking system. Additionally, autonomous forklifts can handle heavy loads, which is an ideal fit for a company like Campbell’s.

How did the partnership begin???

Campbell's supply chain operation consists of a complex network of manufacturing and warehouse nodes with distribution at its center. The team recognized the need to evolve operations, specifically enhancing how materials were being moved within the warehouse. There was also a need to ensure the work environment remained optimal for associates while maintaining operational output.??

Implementing technology to create better visibility into the operation while also generating the flexibility needed to react appropriately and swiftly to any sudden changes in the market was the solution. This is how the partnership between Campbell’s, Crown Equipment and DHL Supply Chain began.??

Why autonomous forklifts???

Autonomous forklifts provide safety benefits that protect warehouse associates. Accidents arise in dense, constrained warehouses due to natural, human error. A miscalculation on the highest rack with a 3,000-pound pallet could be catastrophic, so taking associates out of harm’s way is an important benefit of this type of solution.??

Another benefit is cost savings. For example, autonomous forklifts do not need light to operate. So, the autonomous forklift works 24/7 with minimal supervision and without the overhead cost of full-warehouse lighting. There is also a case for inventory accuracy. Limiting the chance of human error ensures that pallets are put away and scanned accurately. More benefits are expected to appear as the solution begins to scale up.??

Where do we go from here???

Plans are in place to expand this solution as quickly as possible, not only in the Campbell’s facility but also across other DHL Supply Chain warehouses. While implementing the expansion, we are evaluating solution improvements including a more seamless charging experience and expanding integration capabilities of the forklifts.??

This first North America installation of autonomous forklifts represents a significant step in DHL Supply Chain’s efforts to accelerate the deployment of indoor robotic transport in its more than 2,200 warehouses worldwide. DHL Supply Chain’s commitment to continuous innovation and digital transformation represents the next frontier in end-to-end supply chain optimization, from the warehouse to packaging and transportation.??

If you want to learn more about this solution, listen to the full "All Business. No Boundaries." podcast episode?here .?