Pre-sales Concepting and Solution Identification: The journey began with close collaboration with the retailer, identifying the specific needs and challenges of their distribution center. This phase involved rich, obsessive customer collaboration to ensure that the proposed solution was not only feasible but also aligned with the retailer’s operational goals. 

Detailed Engineering Design: Mujin’s engineers developed a detailed layout and specification for each subsystem, focusing on precision and integration. This phase included the sizing and specification of each component to ensure optimal performance and seamless operation within the existing infrastructure. 

Procurement: Mujin’s hardware-agnostic approach allowed for greater flexibility in selecting components, optimizing the supply chain for cost, quality, and lead time. This approach ensured that the best possible components were chosen for each part of the system, driving both efficiency and cost-effectiveness. 

Build: This phase included the thorough assembly, power-on, and commissioning of each subsystem. Rigorous testing and quality assurance were conducted to weed out early component failures and ensure reliability in line with engineering first principles. 

Deployment: Guided by experienced Mujin engineers and project managers, the installation process was executed with precision. Deep software integration with the retailer’s Warehouse Management System (WMS) was performed, followed by comprehensive system testing to ensure that all components worked together seamlessly. 

Go-Live and After-Support: The final phase involved transitioning the system to full operational status, backed by Mujin’s remote maintenance capabilities. A dedicated service team was made available, offering a range of Service Level Agreements (SLAs) and maintenance plans to ensure ongoing support and system optimization. 

Safety-first Design Protocol: Following RIA industry standards, Mujin conducted a thorough risk assessment from the system design concept stage through to detailed engineering and deployment. This protocol mitigated and eliminated potential user and operator hazards, ensuring a safe working environment. 

Implementation of Robot Cells: Mujin’s team installed and configured the robot cells to handle mixed-SKU pallets effectively, ensuring that each cell met the retailer’s specific needs. 

Integration of Vision Systems: Advanced vision systems were integrated into the solution, providing precise identification and handling of diverse products. The auto-calibration feature ensured ongoing accuracy with minimal maintenance. 

Deployment of AGVs: Automated Guided Vehicles (AGVs) were deployed to maintain a continuous flow of pallets within the facility, eliminating the single points of failure found in traditional systems. High-security, end-to-end encryption was used in fleet manager communication to ensure reliability. 

Utilization of Real-Time Digital Twin: The MujinController platform’s real-time digital twin provided continuous feedback, allowing the system to dynamically adjust to changes or anomalies in pallet loads. This feature also created a data-rich environment for next-generation analytics and user dashboards. 

System Testing and Commissioning: Before full-scale deployment, rigorous testing was conducted to ensure that all components worked seamlessly together. The MujinController’s advanced capabilities enabled efficient commissioning, setting the stage for a smooth transition to operational use. 

Post-deployment Software Remote Support: Mujin’s post-deployment support featured over-the-air remote maintenance, ensuring regular software improvements and system upgrades that increased performance over time. This continuous improvement approach is key in addressing corner cases that may emerge after initial deployment. 

Increased Throughput: One of the most notable outcomes was the substantial increase in throughput. The distribution center achieved a processing rate of up to 660 cases per hour per robot cell, a remarkable improvement that directly contributed to the facility’s ability to handle higher volumes with ease. This increase in throughput enabled the retailer to meet growing demand without compromising on efficiency. 

Enhanced Accuracy: The automation solution drastically reduced errors that were previously common in manual handling processes. With the precision of the MujinController’s real-time digital twin and the advanced vision systems in place, the system achieved near-perfect accuracy in identifying, handling, and sorting a wide range of SKUs. This enhancement in accuracy not only reduced rework and returns but also bolstered the overall reliability of the distribution center’s operations. 

Reduced Physical Strain: The shift from manual handling to automated processes significantly alleviated the physical demands on the distribution center’s workforce. By automating the most labor-intensive tasks, Mujin’s solution allowed employees to focus on more strategic activities, leading to improved job satisfaction and reduced turnover. This change also contributed to a safer working environment, as it minimized the risk of injuries associated with repetitive lifting and handling. 

Operational Efficiency: The streamlined processes resulting from Mujin’s automation solution translated into higher overall productivity. The integration of Automated Guided Vehicles (AGVs) and the intelligent coordination provided by the MujinController eliminated bottlenecks, reduced downtime, and optimized the flow of goods throughout the facility. These improvements not only enhanced the distribution center’s operational efficiency but also reduced its operational costs. 

Continuous Improvement: The real-time digital twin within the MujinController platform played a critical role in driving continuous improvement. By providing a comprehensive, data-rich environment, the platform enabled ongoing optimization of the system’s performance. Over-the-air updates and remote maintenance ensured that the system remained at the cutting edge of technology, adapting to new challenges and opportunities as they arose.