Bringing Intelligent Automation to 3PL Fulfillment

When RG Group set out to automate order fulfillment for a major 3PL, they needed a solution that could handle high SKU variety, mixed pallet building, and seamless integration with existing workflows. To achieve this, they partnered with Mujin to deploy an intelligent robotic case picking (RCP) system powered by MujinOS. This collaboration enabled faster, more reliable fulfillment while reducing the labor demands of manual palletizing.

The Challenge

Allen Distribution, a leading 3PL provider, sought a highly automated palletizing system to optimize their warehouse operations. Key requirements included:

  • Efficient mixed-SKU palletizing that follows specific stacking rules.
  • Seamless integration with existing warehouse management systems (WMS).
  • High system throughput and reliability to meet peak order demands.
  • Advanced error recovery to prevent delays due to SKU misalignment or missing inventory.

Given the complexity of multi-SKU fulfillment and the need for continuous operation with minimal manual intervention, a conventional robotic system wouldn’t suffice. A smarter, more flexible approach was needed.

Mujin’s Solution

At the heart of this project was MujinOS, a robotics control platform designed to enable fully autonomous, intelligent case picking. Mujin’s technology orchestrates robotic motion, vision, and fleet management to build order pallets with optimal efficiency.

How MujinOS Enhanced the System:

  • Machine Intelligence for Precise Order Building
    • Mujin’s vision system and MujinPack software ensured cases, bags, and blocks were stacked efficiently while following Allen Distribution’s strict packing rules.
    • The Mujin Gripper provided reliable handling of diverse package types, including heavy-duty poly bags.
  • Seamless AGV & WMS Integration
    • AGVs delivered SKU pallets from storage to the robot cell, ensuring a steady material flow.
    • MujinOS interfaced with the WMS to track inventory, update order progress, and coordinate real-time SKU changes.
  • Automated Exception Handling
    • MujinOS detected and responded to SKU misalignment, missing inventory, and incorrect order sequencing—eliminating costly manual intervention.
    • When an incorrect SKU arrived, MujinOS rerouted AGVs to correct the issue before order fulfillment was impacted.

Seamless Integration with RG Group’s System

RG Group leveraged Mujin’s hardware-agnostic platform to deploy a system that worked seamlessly with existing warehouse infrastructure. The Mujin Fleet Controller synchronized AGV movements, ensuring precise inventory positioning and on-time deliveries to the robot cell.

As a robotics system integrator, RG Group was able to implement this project without overhauling Allen Distribution’s current operations, making automation scalable, cost-effective, and future-proof.

Driving Higher Uptime and Order Throughput

With MujinOS at the helm, the system achieved exceptional uptime and efficiency:

  • 4,125 bags picked per day at peak throughput.
  • 275 picks per hour per robot cell.
  • Automatic slip-sheet handling to streamline pallet construction.
  • Error rate below 2%, ensuring high accuracy in order fulfillment.

Time and Cost Savings for the 3PL

By integrating MujinOS, RG Group and Allen Distribution benefited from:

  • Faster deployment—Mujin’s pre-configured controllers, vision systems, and fleet management tools reduced installation and testing time.
  • Lower engineering effort—No-code interfaces and digital twin simulation helped minimize on-site configuration work.
  • Scalability—Allen Distribution can now expand automation effortlessly by adding more Mujin-powered robot cells as demand increases.

A Smarter Future for 3PL Automation

The success of this project highlights Mujin’s ability to transform complex warehouse operations with intelligent robotics. By partnering with RG Group, Mujin delivered a future-ready automation solution that enhances efficiency, reduces labor dependencies, and ensures continuous fulfillment at peak performance.

For 3PLs looking to scale their operations with reliable automation, MujinOS provides the intelligence needed to make automation work—every time.