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Types of Warehouse Robots: Automation on the Move | Maveneer

Written by Maveneer | Jun 24, 2025 11:05:01 AM

Introduction

Warehouse operations have undergone a major transformation over the past two decades. What once relied heavily on manual labor and paper-based processes has evolved into a fast-paced, tech-driven environment—driven largely by the rapid adoption of automation and robotics.

As detailed in our guide to warehouse operations, this shift is not just about efficiency—it’s about building scalable, resilient fulfillment networks that can handle today’s complex demands.

Robotics now plays a central role in warehouse optimization. From transporting goods and picking orders to storing inventory and supporting human workers, different types of robots serve different functions—each offering unique advantages.

Understanding the range of available robotics technologies is essential to designing smarter, faster, and safer workflows. In this article, we break down the most common types of warehouse robots and how they fit into a modern process optimization strategy.

Autonomous Mobile Robots (AMRs)

Autonomous Mobile Robots (AMRs) are self-navigating robots that use onboard sensors, cameras, and real-time mapping software to move independently through a warehouse. Unlike AGVs, which follow fixed routes, AMRs dynamically adapt their paths to avoid obstacles and respond to layout changes—making them highly flexible for modern operations.

Applications:

  • Transporting goods between zones
  • Assisting in order picking
  • Replenishing inventory locations
  • Supporting just-in-time workflows


Benefits:

  • Adapts easily to changing warehouse layouts
  • Reduces manual travel and improves efficiency
  • Scales with demand—robots can be added or redeployed as needed

Maveneer offers custom AMR solutions designed to optimize material handling and streamline fulfillment workflows. These systems help facilities reduce congestion, minimize walking time, and increase overall productivity without extensive infrastructure changes.

Automated Guided Vehicles (AGVs)

Automated Guided Vehicles (AGVs) are mobile robots that transport materials along fixed paths using magnetic tape, embedded wires, QR codes, or other guidance systems. Unlike AMRs, AGVs do not make real-time decisions; they follow programmed routes, making them ideal for structured environments with repeatable transport tasks.

Applications:

  • Moving pallets between receiving, storage, and shipping zones
  • Replacing forklifts in repetitive material movement
  • Connecting workstations in manufacturing or kitting environments

Benefits:

  • Precise, predictable movement
  • Reduces the need for human-operated equipment
  • Enhances safety in high-traffic areas

AGV solutions are commonly deployed in facilities where consistency, route discipline, and safety are top priorities—particularly in high-volume operations where forklifts or manual carts are limiting throughput or causing congestion.

Automated Storage and Retrieval Systems (AS/RS)

Automated Storage and Retrieval Systems (AS/RS) are high-density automation solutions that use robotic cranes, shuttles, or vertical lifts to automatically store and retrieve goods from designated locations. These systems are ideal for facilities looking to maximize space utilization and improve inventory accuracy.


Applications:

  • High-density pallet or tote storage
  • Inventory management in fulfillment centers and cold storage
  • Buffering zones for production and order consolidation

Benefits:

  • Maximizes vertical and horizontal space
  • Improves picking accuracy and speed
  • Reduces labor and forklift traffic in dense storage zones

AS/RS solutions are well-suited for operations with high SKU counts, limited space, or fast-turn inventory. They support real-time WMS integration, enabling faster cycle times and improved throughput in both distribution and manufacturing environments.

Robotic Arms

Robotic arms are programmable machines designed to perform precise, repetitive tasks such as picking, placing, sorting, packing, and palletizing. These systems mimic human arm movements but operate with far greater speed, consistency, and accuracy—making them indispensable in modern warehouse and production environments.


Unlike mobile robots, robotic arms are typically stationary and deployed at fixed workstations. They are often integrated with vision systems, conveyor lines, and WMS software for seamless order handling.


Applications:

  • Sorting items by size, SKU, or destination
  • Packing goods into cartons or shipping containers
  • Palletizing and depalletizing cases or totes
  • Automated kitting and assembly in light manufacturing

Benefits:
 
  • High-speed, high-precision execution
  • Consistent performance with minimal errors
  • Reduces ergonomic strain on human workers
  • Capable of operating 24/7 with minimal downtime

Robotic arms are especially effective in facilities with high throughput and repetitive manual tasks. They help reduce labor reliance, improve quality control, and boost overall system reliability when paired with upstream automation like conveyors or AS/RS.

Goods-to-Person (GTP) Systems

 
Goods-to-Person (GTP) systems transform traditional picking workflows by bringing inventory directly to warehouse workers, eliminating the need for them to walk long distances through storage aisles. Instead of searching for products, operators remain at ergonomic picking stations while items are delivered via shuttles, vertical lifts, or mobile robots.

Applications:
 
  • E-commerce fulfillment and retail distribution
  • Order picking in high-SKU environments
  • Buffering and sequencing for downstream packing or shipping

Benefits:
 
  • Greatly reduces walking time and physical strain
  • Increases picking speed and accuracy
  • Improves space utilization through dense storage configurations
  • Enables consistent, ergonomic work conditions for operators

GTP systems are especially valuable in high-volume fulfillment centers that prioritize fast order turnaround and labor efficiency. They offer scalable performance and can be easily integrated with WMS platforms and other automated subsystems.

Collaborative Robots (Cobots)

Collaborative robots, or cobots, are designed to work safely alongside human workers in shared warehouse environments. Unlike traditional industrial robots, which are often caged off for safety, cobots are equipped with sensors and force-limiting features that allow them to operate in close proximity to people—without the need for barriers.


Applications:

  • Assisting in repetitive assembly or kitting tasks
  • Augmenting human labor in packaging or labeling stations
  • Supporting ergonomic lifting and placement of heavy or awkward items
  • Handling variable tasks with easy reprogramming

Benefits:

  • Increases overall productivity without replacing workers
  • Reduces strain and risk of injury from repetitive or strenuous tasks
  • Highly flexible and can be redeployed across multiple workflows
  • Faster implementation and lower cost than many fully automated solutions


Cobots are especially useful in facilities looking to enhance existing processes without a full automation overhaul. They’re well-suited for environments with frequent changeovers, high mix/low volume workflows, or skilled human tasks that benefit from robotic support.

Horizontal Carousels

Horizontal carousels are automated storage and retrieval systems that rotate inventory horizontally to bring items directly to a warehouse operator. Think of them as a high-speed, motorized filing cabinet: bins or shelving units spin on a track to position the correct item at the access point—minimizing walking and search time.


These systems are typically used in batch picking environments and are paired with technologies like pick-to-light systems for speed and accuracy.


Applications:

  • Small parts picking in manufacturing or spare parts distribution
  • E-commerce fulfillment with high order line counts
  • Order consolidation zones in distribution centers

Benefits:

  • Optimizes space in low-ceiling or narrow-aisle areas
  • Increases picking accuracy and speed
  • Reduces picker travel time and walking fatigue
  • Ideal for high-SKU, small-item operations

Horizontal carousels are especially effective when integrated into a goods-to-person workflow or deployed alongside vertical lift modules (VLMs) for a layered storage solution that leverages both floor and vertical space.

Vertical Lift Modules (VLMs)

Vertical Lift Modules (VLMs) are enclosed, high-density storage systems that use an automated inserter/extractor to deliver trays of goods to an access window at ergonomic height. By utilizing vertical space, VLMs help warehouses store more inventory in a smaller footprint while streamlining retrieval and improving accuracy.


VLMs are typically integrated with WMS software and often paired with barcode scanning and pick-to-light indicators for fast, precise order fulfillment.


Applications:

  • Storage and picking of small to medium-sized items
  • Inventory consolidation in constrained facilities
  • Secure storage for high-value or serialized products
  • Workstations for kitting, assembly, or order prep

Benefits:

  • Maximizes vertical space without expanding floor area
  • Increases picking speed and accuracy
  • Improves ergonomics by delivering goods to waist-level access points
  • Reduces inventory errors through integrated software and sensors

VLMs are a smart solution for operations looking to increase capacity without expanding footprint, especially in facilities that handle dense SKU profiles or require secure, climate-controlled storage.

Conclusion

Warehouse robotics have become a cornerstone of modern supply chain optimization—supporting faster fulfillment, greater accuracy, improved safety, and scalable growth. From mobile transport systems like AMRs and AGVs, to high-density automation like AS/RS and VLMs, and collaborative solutions like cobots, each robot type serves a specific purpose in enhancing operational performance.


The key to unlocking these benefits lies in selecting the right mix of technologies based on your warehouse’s unique needs—whether that means improving pick accuracy, maximizing storage space, or reducing manual labor.


As warehouse operations continue to evolve, so too will the capabilities of these robotic systems. Investing in the right automation strategy now means building a smarter, more resilient operation for tomorrow.

Ready to get started? Talk to an expert and learn how Maveneer can help you design and integrate the right robotics solution for your warehouse.
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