Integrating Robots
with Your Warehouse Systems:
Benefits, How-Tos, and Best Practices

Julia Bespala
Head of Marketing, Yango Robotics

Running a warehouse is no easy task. With constant pressure to improve productivity, accuracy, and safety, warehouse managers are always on the lookout for innovative solutions. One game-changing technology is the use of robotics. Did you know that more than 70% of warehouses using autonomous mobile robots see major boosts in productivity and efficiency? And by 2025, the number of warehouses using robots is expected to increase by five times. Clearly, robotics can make a big difference.

In this article, we’ll explore the benefits of using robots in warehouses, how to integrate them with your existing systems, and best practices to get the most out of this technology.

Warehouse automation isn’t a new idea, but its use has grown rapidly in recent years. Big companies like Amazon started this trend, showing how robotics can change fulfillment centers by reducing order processing times and errors.
Here are some major benefits that robots bring to warehouses:

• Increased productivity. Robots can work around the clock without getting tired, significantly boosting productivity.
• Improved accuracy. Human errors are common in manual warehouse operations, leading to misplaced items and incorrect orders. Robotics can reduce these mistakes.
• Cost savings. Robots reduce the need for manual labor, lower operational costs, and improve resource use. While the initial cost of robots can be high, the long-term savings are substantial, and the payback period is quite short. For example, at Yango Robotics, we estimate the full payback of our clients’ investments within two to three years.
• Enhanced safety. Warehouses can be dangerous places with heavy machinery and constant movement. Robots help improve safety by taking over dangerous and physically demanding tasks, reducing the risk of injuries.

According to the 2024 MHI Annual Industry Report, Dorman, a leading automotive parts supplier, upgraded its 1 million sq. ft. distribution center by integrating advanced fulfillment AI and 25 autonomous mobile robots to boost efficiency and flexibility. This initiative reduced forklift labor by 30%, saving $4.2 million over three years, cut worker travel time by 50%, and simplified the onboarding process for new associates, significantly enhancing operational performance and analytics visibility.

Implementing robotics is a complex and time-consuming process, but it can be broken down into five key steps. Let’s see how each step works and what you need to keep in mind.

The first thing you need to do is understand your current setup and its weaknesses. This helps identify areas where robots can make the biggest difference.
Look closely at your existing warehouse management system (WMS) and inventory management system (IMS). How well do they handle inventory tracking, order processing, and overall logistics? Assess their strengths and weaknesses that automation can streamline. For instance, your WMS might be excellent at tracking large inventories but struggle with processing individual orders.
Based on your analysis, decide what exactly you need from robotics. Are you aiming to speed up order fulfillment? Reduce labor costs? Improve picking accuracy? Knowing your goals will help you choose the right robotic solutions.
Tip: Talk to your warehouse staff, IT team, and management to get their insights on where they see the biggest challenges and benefits from automation.Implementing robotics is a complex and time-consuming process, but it can be broken down into five key steps. Let’s see how each step works and what you need to keep in mind.

The right robotic solutions fit your specific needs that include the functions robots need to perform and compatibility with your current systems.
First, understand the different types of robots and see which of them suit your needs:

• Autonomous mobile robots (AMRs). AMRs navigate warehouses independently, transporting goods from one location to another. They’re flexible and can adapt to changes in the warehouse environment.
• Automated guided vehicles (AGVs). AGVs follow fixed paths and are ideal for repetitive tasks such as moving items along predetermined routes.
• Robotic arms (Cobots): These are used for complex tasks like picking and placing items with high precision. They can work alongside human workers, enhancing productivity.

Once you know which type of robots you need, explore the market for offerings, checking how compatible they are with your current systems. Robots should enhance your warehouse workflow, not disrupt it. That’s why we advise to opt for hardware-agnostic systems, like the ones we offer at Yango Robotics — these solutions integrate with any warehouse systems.
Factors to consider when selecting robotics:

• Warehouse size. Large warehouses might benefit more from AMRs that can cover vast areas quickly, while smaller facilities will find robotic arms more useful for precise tasks.
• Inventory types. Consider the types of inventory you manage. Heavy, bulky items need different robotic solutions compared to small, delicate items.
• Operational requirements. Assess your workflow needs. Do you need robots for picking, packing, palletizing, or all three? Choose robots that can handle your specific operational demands.Implementing robotics is a complex and time-consuming process, but it can be broken down into five key steps. Let’s see how each step works and what you need to keep in mind.

The final step is to ensure that your robotic solutions are delivering the expected benefits and identify areas for further improvement. To do this, measure the success of these new systems and assess the return on investment.
Start by defining KPIs. These metrics will help you track the performance and impact of the robots on your warehouse operations. Here are some metrics to consider:

• Order fulfillment speed
• Picking accuracy
• Inventory turnover rate
• Labor cost reduction
• Operational downtime

Regularly tracking these indicators will give you a clear idea of the improvements brought by your robotic systems. Use this data to identify any areas that need adjustment.
It’s also crucial to determine the financial impact of your robotic systems. Conduct a thorough cost-benefit analysis to assess how beneficial they are for your business and decide whether you should scale up. Here’s how to do this:

• Calculate initial costs. Include the cost of robots, integration, training, and any necessary infrastructure changes.
• Estimate ongoing costs. Factor in maintenance, repairs, and potential upgrades.
• Quantify benefits. Measure the financial benefits gained from increased efficiency, reduced errors, and labor cost savings.
• Determine payback period. Calculate how long it will take to recoup your investment in robotics.

Use the insights gained from your KPI tracking and financial analysis to review and adjust your robotic systems and workflows.
And that’s it! That’s the entire robotics integration process in a nutshell.