Robotics in intralogistics - study and guidelines

The latest study by Unitechnik shows that the spread of robotics has not yet been widespread: while almost 48% of the companies surveyed have already implemented robotic solutions, the remaining 52% have not yet done so. This result makes it clear that despite growing demands on modern intralogistics, increasing competitive intensity and clearly recognizable efficiency potential, many companies are still hesitant to integrate robot-supported automation into their logistics processes.

Most companies that already use robotics automate material transport in production or in the logistics center, for example using AGVs or AMR. Other respondents stated that robotics is used in their working environment for palletizing and depalletizing, for example, but also for picking and packing. Figure 4 shows the current and future use of robotics for various work processes.

On the other hand, there are companies that have yet to embrace robotics. There are many reasons for this: in addition to the investment costs and a supposedly high implementation effort, regulatory requirements, safety concerns such as system failures or production downtimes and a shortage of skilled workers also play a role. In intralogistics, it is also apparent that many companies continue to use conventional conveyor technology or do not yet have a fully digitalized infrastructure.

However, the current market situation clearly shows that while some companies are already benefiting from the advantages of robotics, there is still considerable potential for innovation and investment in many areas. The results of the study show a clear trend towards a willingness to invest: the majority of respondents see a high potential for optimization through robotic solutions. Around three quarters (74%) of all survey participants stated that they intend to invest in initial or further robotic systems in the future.

The main drivers of this development are the increasing demands for fast and error-free material flows, the ongoing shortage of skilled workers and increasing competitive pressure, particularly from global logistics groups and e-commerce giants.

Companies that have already implemented their first robotic solutions see further potential for optimizing their processes with additional systems. In intralogistics in particular, robot-assisted automation has been shown to stabilize material flows, reduce bottlenecks and enable data-based decisions. Many of these companies are therefore gradually expanding their existing installations with additional robots, sensors and AI-supported technologies in order to make logistics processes even more efficient and secure their competitiveness in an increasingly digitalized industry.

At the same time, society's perception of robotics is changing noticeably: what used to be seen as an exclusive and complex technology has long since become part of everyday life, for example in the form of robotic mowers and vacuum cleaners in private households.

Why not invest in robotics?

Robotic systems make intralogistics fit for the future, but also require investment. The companies that took part in the study are also aware of this. For 68 percent of the survey participants, supposedly high investment costs are the biggest obstacle to implementing robotics. But why is robotics so cost-intensive - and why is the investment still worthwhile?

The costs for robotic systems are made up of several factors

• Acquisition costs: Modern robotics solutions, especially AMR, require highly developed sensor technology and precision mechanics.
• Infrastructure and conversions: Depending on the business environment, the introduction of robotics may require structural changes to the warehouse or production hall, such as refurbishment of floors or new safety equipment.
• Employee training: In order for robotics to be used efficiently, employees must be trained in its operation, maintenance and monitoring.
• Maintenance and operating costs: After purchase, there are ongoing costs for software updates, spare parts and maintenance to ensure smooth use.

The study shows that interface integration is another key hurdle for 43% of respondents. The seamless integration of new robotic systems into existing IT and logistics structures requires careful planning and often extensive adjustments. This shows the particular importance of a system integrator when introducing robotic systems.

At the same time, high security requirements (38 percent) and employee acceptance (34 percent) are perceived risks: Acceptance of new technologies by the workforce remains a challenge for the transition to Industry 4.0.

Other relevant obstacles are the dependence on robotics (33 percent) in terms of potential disruptions and the lack of flexibility of the systems (31 percent), particularly in dynamic logistics environments. Companies also fear that the high costs for service and maintenance (30 percent) will increase ongoing operating costs too much.

While some companies also fear that day-to-day business will be impaired during the migration (13%) and that employees will need a lot of training (14%), modern training concepts and scalable implementation steps from Unitechnik offer solutions to minimize these risks.

The results show that successful robotics integration requires more than just technological investment - it requires a well thought-out strategy that takes both economic and operational factors into account. This includes a clear definition of objectives, a detailed analysis of existing logistics processes and the selection of robotic systems that can be precisely integrated into the existing material flow. At the same time, companies need to assess how well new technologies such as sensor technology, AI, data analysis and mobile robotics solutions harmonize with their existing systems. Organizational aspects also play a role: employees must be trained, interfaces must be intelligently designed and workflows must be adapted to the new automation processes. Only when technological, process-related and personnel factors work together can the full potential of modern robotics be exploited and sustainable, stable and scalable intralogistics be established in the industry.

Why invest in robotics?

Constantly increasing productivity and growth are no longer just a competitive advantage - they are necessities. Companies that do not constantly work more efficiently lose market share and profitability and risk having to take a back seat in the long term. Over 80 percent of those surveyed see robotics as a decisive lever for speeding up work processes and making optimum use of resources. Whether in production, transportation or goods handling, robots work around the clock with constant precision - an invaluable advantage in a dynamic logistics world.

But it's not just about speed: half of the survey participants expect considerable savings in operating costs through the use of robotics. In addition, shorter throughput times ensure greater flexibility and enable a faster response to customer requirements and market changes.

Other decisive factors are increased safety and a minimized error rate, which 56% of companies perceive as an advantage. Robots take over dangerous or monotonous tasks and thus not only reduce the risk of accidents, but also ensure consistently high quality. At the same time, automation can help mitigate the shortage of skilled workers - almost 70% of respondents see robotics as a solution to reduce manual tasks and relieve the ergonomic burden on valuable workers.

Strategic advantages also play a role: more efficient use of space (12%) and greater digitalization of processes (39%) are decisive arguments for many companies. The image of a brand can also benefit significantly - 15% of companies expect implementation to strengthen their market position.

Investing in robotics is far more than just technological modernization - it is a step towards a more productive, safer and more sustainable future. Companies that invest in automation now are laying the foundations for long-term competitiveness. By using intelligent robot systems, material flows can be stabilized, error rates reduced and processes designed in such a way that they function reliably even under growing cost pressure and increasing requirements. At the same time, the integration of sensors, AI and data-based technologies enables ongoing optimization of processes, allowing companies to react more flexibly to market changes. Robotics is therefore developing into a strategic tool that not only increases efficiency in the short term, but also forms the basis for future-proof and resilient intralogistics in the long term.

Material transportation and order picking

At 42%, companies are most willing to integrate robotic systems in the future in order picking (e.g. picking robots). The survey participants also see great potential for optimizing their material flows in the transport of materials in the logistics center (41%), in production (29%) and on the factory premises (16%).

Palletizing and packing

Pallets play a major role in the intralogistics of German companies. While they are depalletized at goods receipt, cartons have to be repacked for further shipping and stacked on pallets with stretch film to make them safe for transport. These are all tasks that could be taken over by robotics in the future: A good 25 percent of respondents would consider palletizing robots in the future to load pallets in preparation for shipping, and just under 19 percent want to unload their pallets in goods receiving with the help of such solutions.

Truck loading

Another important field of application for robotics is also emerging: 21% of companies are planning to use automated systems for loading trucks, an area in which manual processes have dominated to date. A number of companies are currently researching the automation of this demanding task. The challenge: to be faster than humans. The service life of trucks is a critical factor.

Returns processing

Very few companies (5 percent) are planning to use robotics in connection with returns. However, this could soon change, as advances in the field of artificial intelligence are opening up new possibilities: In future, robots could automatically inspect, classify and sort incoming goods, open or reseal packaging and thus significantly speed up manual inspection processes. In times of rising return rates, particularly in e-commerce, robotics could help to make returns processing more efficient, less costly and less labor-intensive.

Future outlook: popular systems

Driverless transport systems and autonomous mobile robots are very popular with German companies. A decisive majority of 75 percent of respondents plan to invest in these technologies. No wonder, as AGVs and AMRs enable highly automated, responsive intralogistics, relieve employees of time-consuming transport tasks and optimize the flow of materials through intelligent route planning.

Other robotic solutions also remain in demand: 46% of companies see potential in pick-and-place robots, which enable precise and fast picking of goods and therefore primarily take over monotonous tasks.

39 percent want to invest in articulated robots that can perform universal tasks in a small space. Gantry robots that can also stack heavy cartons and containers and thus relieve people of physically heavy work are of interest to a quarter of those surveyed.

The study shows: The future of intralogistics is driverless, automated and highly flexible.

Criteria for selecting the provider

A good price-performance ratio is the most important factor for 74% of respondents when implementing automation solutions. The frequently mentioned factors of planning competence for logistics and material flow (69 percent) and interface competence (44 percent) show that robot systems are not islands, but must be seamlessly integrated into the existing material flow. This integration must be carefully planned and implemented.

Before switching to a robotized working environment, 44% of survey participants attach importance to comprehensive testing (e.g. by emulating the entire system) and 24% want structure and full transparency in the implementation process. Individual support also plays a central role for many companies: 53% of those surveyed stated that this aspect is particularly important to them.

General contractors and system integrators specializing in robotics - with a total of over 90 percent, these are the most popular service providers for the implementation of robotics solutions. Unitechnik Systems GmbH combines both advantages: As a manufacturer-independent system integrator and general contractor, Unitechnik accompanies the entire integration cycle of robotic systems: from planning and implementation to continuous optimization - with a reliable 24-hour service. This makes the general contractor an absolute benchmark for German companies that want to make their intralogistics fit for the future. Only a good eight percent of those surveyed would commission robot manufacturers for their robotic systems. As a lifetime partner and complete supplier, Unitechnik is suitable for all requirements that companies have for automated robotic systems for their intralogistics: Namely, experienced project managers and fixed contact persons at the supplier throughout the entire project and beyond are also particularly important to the respondents.

Unitechnik's references include well-known companies from a wide range of industries such as B.Braun, Borgmeier, Claas, Dehn, Emirates, Hela, Linde Gas, Nobilia, Otto Fuchs, Soennecken, Turck and Wildeboer. For this reason, the system integrator has a wide range of experience and meets its customers with technical expertise in a variety of industries.