The Ultimate Guide to AMRs

AMR vs AGV: What’s the difference?

The key difference between AGVs (Automated Guided Vehicles) and AMRs lies in the way they navigate around a warehouse.

AGVs follow fixed paths using predefined tracks or markers, from colored stripes to QR codes.

AMRs, a newer technology, employ advanced sensors, AI, and real-time mapping to navigate dynamic environments autonomously, making them more adaptable for warehouses with changing layouts or unpredictable obstacles.

How are AMR Robots used in warehouses?

AMRs play a crucial role in automating and streamlining various warehouse tasks. From assisting employees with picking to transporting goods across the facility, they improve operational efficiency and reduce manual labor.

Two primary types of AMRs used in warehouses are Person-to-Goods (PTG) and Goods-to-Person (GTP) systems, each offering distinct advantages for different workflows.

Person-to-Goods (PTG) AMRs

Person-to-goods AMRs are industrial robots that augment the picking process by guiding employees through the warehouse via the most efficient routes to the right storage location or inventory. They may be designed simply to guide, or to then transport picked items across the warehouse—reducing employee fatigue.

Material Handling (Pallet or goods-to-person – GTP) AMRs

Material handling AMRs, sometimes called goods-to-person or pallet-to-person AMRs, bring items to stationary employees at workstations for picking or sorting. They locate inventory autonomously and retrieve it using a lifting mechanism such as a forklift or jack, before transporting it across the warehouse. Depending on their size and configuration, GTP AMRs can handle a variety of payloads, from full pallets to eaches.

Benefits of AMRs

From boosting operational efficiency to enhancing workplace safety, AMRs provide flexibility and scalability that few traditional automation systems or industrial robots can match. Below are some of the key advantages of using AMRs in modern warehouses.

Fast, flexible deployment

AMRs are easily deployed and can adapt to operate in a wide range of warehouse environments and conditions, from temperature-controlled environments to complex, dynamic or unpredictable layouts.

Scalable technology

Operators can respond to changes in demand, staffing and workload by scaling their AMR fleet both up and down. This in turn means companies save on labor and are less impacted by difficult and competitive labor market conditions, or during seasonal peaks.

Minimizes strenuous manual work

A study by KPMG discovered leaders in numerous industries believe that 63% of monotonous operational tasks can be done by robots. AMRs automate more taxing, time-consuming tasks such as transporting heavy goods around a warehouse or locating inventory, enabling employees to concentrate on more rewarding tasks.

Fits your existing infrastructure

Many AMRs are designed to ‘hook into’ your existing warehouse management system (WMS) or enterprise resource planning (ERP) software, though the extent varies. Our AMR, Chuck, is capable of connecting and exchanging data with your WMS/ERP via WiFi from the moment of deployment.

Real-time decision-making

Employees no longer have to rely on guesswork when reaching and selecting stock. The software enables AMRs to identify stock with 100% accuracy and plan the best physical paths to get to inventory and transport it efficiently.

Minimal training needed

While other industrial robots may require comprehensive operational and safety training, getting your employees familiar with autonomous mobile robots is much more straightforward. For example, it only takes a few minutes for employees to learn how to interact with Chuck and start picking.

Makes work safer for employees

Carrying heavy loads or handling hazardous materials increases the likelihood of workplace injuries and employee burnout. AMRs are designed to transport materials of varying sizes and weights with ease, reducing the need for employees to do those physically demanding or hazardous tasks and creating a healthier, safer workplace.

Timeline of AMR adoption

Over the years, advances in navigation systems, sensors, and computing power have shaped industrial robots into the versatile, intelligent machines we see in modern warehouses today. Below is a timeline highlighting key moments in their evolution.

 

Types of AMR

The AMR landscape is rapidly evolving, as new technologies enable new ways of operating. As is the case in any evolving technology delivered by multiple vendors, this has given rise to a number of sub-categories of AMR, the lines between which are often blurred. At a basic level, AMR types include:

 

Applications of Autonomous Mobile Robots

When it comes to selecting between AMRs and other forms of automation, or between one type of AMR or another, it’s important to consider what kind of action or task the AMR will be required to perform. This will determine the most suitable type of robot for you.

Storage and Retrieval: Efficient inventory access

AMRs improve storage and retrieval by autonomously locating and transporting items to or from storage areas, reducing search and retrieval times. Using built-in navigation and sensor technologies, AMRs can locate specific SKUs or bins, optimizing how items are stored based on demand frequency. This minimizes downtime and helps operators quickly access inventory, supporting faster order fulfillment and reducing strain on employees tasked with retrieving heavy or hard-to-reach items.

Trailer Load and Unload: Simplifying dock operations

AMRs streamline the loading and unloading process by autonomously transporting goods between trailers and staging areas or warehouse locations. Equipped with precise navigation and lifting capabilities, AMRs can handle various load types, reducing reliance on manual labor and speeding up dock operations. By automating these labor-intensive tasks, AMRs help prevent bottlenecks at receiving and shipping docks, improving overall warehouse efficiency and reducing unloading times during peak periods.

Picking: Optimize your inventory

Employees no longer need to waste time walking the warehouse to fulfill a single order. Instead, AMRs travel between pickers or zones in order to complete them, enabling employees to focus on staying on task within a manageable area. In the case of Person-To-Goods AMRs, employees are guided within their assigned zones, using software like Chuck’s system-directed picking, to the locations of required items, boosting pick rates. They then place those items into a container on the AMR before it travels to the next 'pick zone' to collect more items with other employees until the order is complete.

Replenishment: No more out-of-stocks

AMRs ensure replenishment is completed at the right time to meet future orders and delivery promises. Software identifies when stock is running low, notifying employees or triggering a restocking workflow. Cases of inventory are placed on the AMR before it autonomously transports them to locations for pick replenishment. With Person-to-Goods AMRs, employees are directed through the tasks to minimize walk time and improve restock accuracy.

Sortation: Streamline sorting orders

Another benefit of AMRs is their ability to automate and streamline the sortation process. Specially designed sortation AMRs come with a range of technologies to handle different items and materials, depending on the model. These include conveyor rollers, tilt trays and cross-belt systems. When items for sorting are placed into the AMR, it scans their barcodes, brings them to a designated location and then shifts or tilts them into the assigned container. AMRs can also manage the transportation of items from the final stop in the picking process to stations, enabling employees to spend most of their time sorting items into orders.

Returns: Maximize your returns profits

With short product cycles and high return rates for some industries, operations need agile systems to maximize the sales value of returned items. Autonomous mobile robots can be deployed to help with returns so those items can be resold in good time, retaining as much margin as possible. As with replenishment, AMRs direct employees through every step in the putaway process.

What technologies does AMR use?

AMRs are capable of autonomy thanks to a variety of advanced sensors that enable them to truly understand their surroundings. By combining data from these sensors—a process known as sensor fusion—these advanced industrial robots obtain a more comprehensive and precise perception of their surroundings. Some of the most common sensors include:

SLAM (Simultaneous Localisation And Mapping)

This algorithm is used by the AMR to create a map of the facility and locate itself within that map. This allows it to visualize an unknown area for path planning and identify obstacles to avoid obstructions.

Computer vision

Computer vision, enabled by AI, enables AMRs to draw meaning from data captured from cameras. This helps them understand and interpret the surrounding environment, recognizing people and unexpected obstacles along their route.

LiDAR

Short for ‘light detection and ranging’, this type of sensor uses a laser beam to determine the distance from an object or create a complete view of its surroundings.

Sonar

No longer limited to submarines, Sonar is similar to LiDAR—but uses acoustic pulses rather than light. By analyzing the echoes to calculate the distances of objects, Sonar enables AMRs to navigate without natural light or in environments where strong light interference is present.

Gyroscopes

Gyroscopes help AMRs maintain balance and orientation as they move through their environment. By measuring angular velocity, they ensure smooth navigation, especially in environments where precision turns or stability are crucial.

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The data from these sensors is then processed using software. This software ultimately defines how capable an AMR is compared to its competitors. AMR software may be powered by both traditional algorithms and modern artificial intelligence (AI).

Many AMRs in operation today rely on classic algorithmic computation to handle navigation, pathfinding, and task management. This approach remains effective, offering reliability and precision without the computational demands of full AI systems. However, AI provides additional (and evolving) capabilities, such as real-time decision-making, dynamic learning, and adaptability in complex environments.

Whether using traditional algorithms or artificial intelligence, both approaches are valuable and practical, depending on the specific application and operational needs.

Which industries are AMRs most suited to?

AMRs can automate a myriad of tasks in warehousing for a wide range of industries and provide huge gains in operational efficiency. Industries include, but are not limited to:

Pharmaceuticals

• AMRs help employees quickly locate and pick medical products with speed and precision, allowing them to meet the demands of short delivery times. 
• AMRs reduce human error by improving the pick accuracy of standardized batches necessary to meet a specific level of quality. 
• Some AMRs like Chuck leverage smart software to keep track of inventory and prioritize the items picked based on drug expiration dates and freshness levels.

Healthcare

• AMRs can work in hazardous environments or with noxious materials.
• AMRs can handle menial tasks like delivering medication, meals and medical supplies 
• AMRs assist doctors and nurses with care by monitoring patients throughout the hospital

Fashion & Apparel

• AMRs can alleviate the pressures of new seasons, sales and peak shopping periods (such as Black Friday) by enabling the workforce to quickly and efficiently respond to these changes in demand. 
• AMRs ensure accurate and proactive replenishment, preventing issues like stockout. 
• AMRs help with the returns putaway process, which is crucial for fashion retailers as they deal with relatively high return rates. 

Electronics

• AMRs quickly replenish new electronics to respond to sudden fluctuations in consumer demand often experienced by the electronics sector.
• By automating time-consuming tasks, AMRs reduce cycle times and increase throughput.
• Electronic companies rely on getting products to market more and more quickly, so fulfillment speed is key. AMRs can be deployed at scale, meaning businesses can expand their AMR fleets to accelerate throughput.

Industrial & Automotive

• AMRs optimize intralogistics workflows by managing the transportation of car or engine components between assembly lines and around the facility.
• AMRs help employees find critical components in time to meet tight production schedules.
• AMRs do the lifting and carrying of heavy components, reducing the chance of workplace injury and combating operator fatigue.

3PL (Third-Party Logistics)

• AMRs enable 3PL providers to adapt rapidly to varying client needs, fluctuating demands, seasonal peaks, or unexpected client requests by easily scaling their fleet.
• By automating tasks like sorting, putaway, and picking, AMRs improve throughput while reducing manual labor needs, allowing 3PLs to handle diverse inventory types for multiple clients with greater efficiency.
• Integration with WMS and ERP systems allows AMRs to deliver real-time updates on inventory levels, ensuring smooth communication between the warehouse and clients.

What are some key considerations in choosing an AMR?

Congestion	A large fleet of AMRs requires consideration into how it will be managed, maintained, and operated as a single, coordinated workforce. Individual autonomy is fantastic, but when scaled up to tens or even hundreds of AMRs, it’s important to consider how these robots will communicate with each other to ensure there are no collisions and that paths chosen do not interfere with others.
Software Limitations	AMRs are incredibly sophisticated pieces of hardware. Yet for all the servos and electronics contained within, it’s the software and algorithms running on the robot and in the cloud that makes the difference. Poorly coded software or badly trained AI will cause a failure long before the hardware fails, so it’s important to consider the reliability of the solution.
Functional Safety	Many AMRs are designed as ‘cobots’ to work alongside their human counterparts, yet this requires them to operate safely under any circumstances. The IEC61508 standard for industrial applications sets stringent requirements for any robot operating in proximity to humans, and abiding by this should factor into your choice of AMR.
Sensor (Con)fusion	AMRs rely on sensor fusion, combining the outputs of all of their sensors to generate a navigable map of the warehouse in real-time. If those sensors become dirty, fogged, scratched, or damaged, their outputs may decrease significantly in accuracy, leading to errors in algorithmic calculations. Sensors can also be affected by streams of light from spotlights or windows. For this reason, operating an AMR in particularly dirty, humid or dusty environments requires additional regular maintenance.
Support and Maintenance	When selecting an AMR supplier, it is crucial to ensure they offer a robust support and maintenance package tailored to your operation’s specific needs. The ability to quickly replace a failed robot, access parts, and implement software updates can significantly impact your operation's uptime. Consider the urgency of your use case—for instance, a pharmaceutical supplier handling sensitive prescriptions may require higher coverage and faster response times to ensure uninterrupted availability.

 

Can I combine AMR with other types of automation?

The interoperability of many modern automation solutions enables you to get the best of both, or multiple, worlds from combining multiple types of automation system—especially when a GTP and PTG system is combined.

AMRs in particular offer multiple options for augmenting your existing automations solutions. For instance, Chuck AMR can retrieve awkward inventory that only fits on traditional racking and cannot be stored in the Ocado Storage and Retrieval System (OSRS).

Conveyors

By combining an AMR with conveyor systems, operations gain flexibility by allowing AMRs to transport goods across areas where fixed conveyors aren’t feasible, creating seamless connections across warehouse zones.

Automated Storage and Retrieval Systems (ASRS)

By combining an AMR with ASRS, warehouses can retrieve items from ASRS picking stations and deliver them to packing or sorting areas, making ASRS operations more responsive to demand changes.

Robotic picking and sortation

By combining an AMR with robotic picking and sortation systems, goods are efficiently transported from robotic picking stations to different processing or packing areas, speeding up and enhancing order fulfillment accuracy.

Industry-specific sortation systems

By combining an AMR with industry-specific sortation systems (e.g., A-Frame, used in fulfillment of pharmaceuticals), warehouses in specialized sectors can streamline high-frequency order fulfillment, with AMRs collecting and moving items quickly and accurately to the next stage.

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We hope this guide has given you a deeper understanding of AMRs, from how they work and the value they can provide an operation to the technologies and software that enables them to perform as they do.

The right AMR can offer an incredibly agile solution, enabling significant efficiency gains as the sole automated system. But it’s just as effective as a stepping stone to larger, more elaborate automated projects, such as deploying ASRS.