Is the future of e-commerce fulfillment limited to standardized products and packaging? When facing bulky, irregularly shaped, or specialty items, how can logistics automation overcome these bottlenecks? The case of NorthShore Care Supply offers a fresh perspective. This adult incontinence product e-commerce company is pioneering a new path for large-item fulfillment by deploying autonomous mobile robots (AMRs) to upgrade traditional cart-picking operations into efficient automated processes.
The Evolution and Application of AMR Technology in Logistics
In recent years, autonomous mobile robots (AMRs) have transitioned from emerging technology to essential components in the material handling toolkit. The logistics sector, particularly third-party logistics (3PL) providers like DHL, GEODIS, Rakuten Super Logistics, and UPS, have successfully implemented AMR solutions, demonstrating their potential to enhance efficiency and reduce costs.
Leading AMR solution providers such as Locus Robotics, inVia Robotics, and 6 River Systems have emerged, each with distinct technological implementations and strategic focuses. Their common goal remains addressing widespread efficiency challenges in e-commerce fulfillment, especially with standardized products and packaging. In these scenarios, AMRs have evolved from cutting-edge technology to established best practices.
The Next Frontier: Expanding AMR Applications
Field observations at Waypoint Robotics' New Hampshire headquarters and NorthShore Care Supply's Illinois distribution center reveal AMR technology entering a new phase characterized by:
- Broader application scenarios: AMRs are being deployed to solve more complex fulfillment challenges, including handling unique product dimensions and packaging requirements.
- Expanding user base: As technology matures and costs decrease, AMRs are becoming accessible to small and medium enterprises. Compared to multi-million-dollar shuttle systems, AMRs offer more affordable, flexible solutions tailored to SME needs.
NorthShore Care Supply's implementation serves as compelling evidence of this evolution, demonstrating innovative AMR applications for oversized product picking.
NorthShore Care: Leading the Incontinence Product E-Commerce Market
As a market leader in adult incontinence products, NorthShore primarily sells directly to consumers online while also serving institutional clients. Most orders involve full-case picking, with only minimal single-item picking required.
The company's products present unique fulfillment challenges: they're bulky, heavy, and time-sensitive due to customers' urgent needs. Traditional warehouse operations involved employees pushing three-tier carts through facilities—a labor-intensive, inefficient process ill-suited for business growth.
"The carts were extremely heavy, and this picking method couldn't scale with our growth," recalled Adam Greenberg, company president and founder. When designing their new distribution center, Greenberg prioritized overcoming these limitations while preparing for future expansion.
Innovative Solution: AMR-Powered Cart-to-Picker System
Rather than simply replacing carts with AMRs, NorthShore implemented an innovative hybrid solution developed with Numina Group, featuring Waypoint Robotics' heavy-duty AMRs capable of moving large carts (up to 700-pound capacity). Meanwhile, pickers remain stationed in designated zones, selecting items from shelves onto the mobile carts.
This approach offers distinct advantages:
- Superior load capacity: Specially designed AMRs accommodate NorthShore's oversized products.
- Reduced robot count: While traditional AMR solutions might require 30 robots, this system handles approximately 3,500 daily orders with just six AMRs.
- Enhanced picking efficiency: Stationary pickers minimize walking distances, significantly boosting productivity.
Optimized Details: Floor-Level Pallet Racking
The solution incorporates floor-level pallet racking in picking zones, allowing multiple pallets of fast-moving goods to be stored accessibly. This design enables quick picking from the front while permitting replenishment from the rear, further streamlining operations.
Strategic Outcomes: Achieving Multiple Objectives
The AMR implementation successfully met Greenberg's strategic goals:
- Supporting growth: The new facility's expanded capacity accommodates business expansion.
- Reducing labor dependence: Automated processes mitigate workforce shortages.
- Minimizing product contact: Reduced manual handling became particularly valuable during pandemic conditions.
Greenberg emphasized their technology adoption philosophy: "We wanted to be a leader, not a bleeder. While we avoid being first adopters, we actively collaborate with technology providers seeking beta sites to validate their innovations."
NorthShore's case demonstrates AMRs' applicability beyond standardized e-commerce fulfillment, proving their effectiveness for oversized items. This implementation also signals broader AMR adoption trends: expansion from standardized to customized scenarios, and penetration from large enterprises to SMEs.
Conclusion: AMRs Reshaping Logistics Paradigms
NorthShore's success illustrates AMRs' transformative potential in logistics. By creatively implementing this technology, businesses can transcend traditional operational constraints, achieving greater efficiency, lower costs, and stronger competitiveness. As the technology continues advancing and becoming more affordable, AMRs will undoubtedly play an increasingly vital role in redefining logistics frameworks and driving industry evolution.