BreakPack solution drastically reduces each picking costs

One of the most complex and expensive tasks in distribution is handling less-than-case quantities, also called breakpack or each picking. The number of touches and steps or travel performed by workers affects the speed and accuracy of e-commerce, omnichannel, micro-fulfillment, and just-in-time inventory replenishment. Symbotic Inc. has reduced the travel and touches associated with each handling with its BreakPack offering.

BreakPack uses machine vision, artificial intelligence, sensors, and routing and tote-maximization algorithms to orchestrate a fleet of autonomous mobile robots (AMRs). Symbotic has also introduced a proprietary, vision-enabled MiniBot to work alongside its core SymBot AMR.

The four cameras onboard each MiniBot are designed to enhance safety, enable collision avoidance, validate item picks, and flag exceptions as it executes tasks with more than 99.9% accuracy, said the company. The MiniBots are designed for maximum uptime, with docking stations that swap onboard batteries in under 30 seconds.

The SymBots transport full cases from storage to ergonomic BreakPack workstations. Workers process less-than-case quantity orders to waiting MiniBots. They travel at speeds up to 4 mph to deliver products to up to 3,000 waiting outbound totes at once.

The BreakPack system can batch orders for greater efficiency than other automated or manual picking methods, which typically pick to less than 24 totes at a time, explained Wilmington, Mass.-based Symbotic. The MiniBot can target placement of its payload within the tote to maximize tote volume utilization and minimize the number of totes shipped.

Each BreakPack tote is designated for a specific location and filled with products from the same category, department, or aisle for each store layout to reduce the need for sorting downstream. This presorting reduces associated costs, enables faster replenishment, and reduces stock-outs, said Symbotic.

The BreakPack system interface is designed for ease of use, reducing training requirements. Symbotic reported that its customers typically achieve a 60% to 80% reduction in picking costs in comparison with traditional or manual picking. Both new and existing warehouses can implement BreakPack and extend the life of existing assets.

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