Gartner: The Problems with Humanoid Robots in Factories

Humanoid robots are unlikely to transform operations beyond pilot testing, Gartner predicts.

To address labour shortages, skills gaps and the growing demand for supply chain efficiency, manufacturers are looking for robot helpers.

Despite advances driven by AI and automation tools, Gartner's analysis indicates that humanoid robots may struggle to move beyond initial trials.

The firm has assessed the viability of robots currently being developed and tested, and believes that fewer than 100 companies will advance humanoids beyond proof of concept trials.

During this period, deployments of these robots will likely be limited to controlled environments rather than the demanding conditions of busy supply chain operations.

The technology gap

Humanoid robots are engineered to replicate human workers through their form and movements.

They have captured significant attention from leaders looking to address ongoing workforce challenges, including labour shortages, skills gaps and increasing labour costs.

These robots often feature AI-enabled systems, machine learning algorithms for task adaptation and advanced sensors for spatial awareness.

The technology aims to bridge the gap between human capabilities and automated efficiency in warehouse environments.

However, the enthusiasm surrounding these robotic workers could exceed their readiness for large-scale deployment.

“The promise of humanoid robots is compelling, but the reality is that the technology remains immature and far from meeting expectations for versatility and cost-effectiveness,” explains Abdil Tunca, Senior Principal Analyst in Gartner’s Supply Chain practice.

“Chief Supply Chain Officers must carefully evaluate readiness and avoid overcommitting resources to solutions that cannot yet deliver on their potential.”

Challenges facing humanoid robots

Through advanced mechanics, humanoid robots replicate human form and movement, making them appear well-suited to warehouse workforces.

Their heads are equipped with sensors and cameras, their arms and grippers enable them to handle objects and their legs allow movement around warehouses or distribution centres.

Human-like design offers theoretical advantages for navigating spaces built for human workers.

However, this familiar form factor may not translate to practical superiority in operational settings.

Gartner says that alternative designs could be better suited for supply chain operations.

The firm points to polyfunctional robots with wheels or sensors in unconventional placements to allow for improved performance and adaptability.

The limitations of humanoid robots become apparent when assessed against the rigorous demands of modern factories.

Current technology struggles to match the versatility and endurance required for continuous warehouse operations.

Although they demonstrate potential, Gartner identifies several limits to their adoption:

• Technological limitations: current models may not meet the complex needs of high-demand warehouses, lacking the required dexterity, intelligence and adaptability
• Integration complexity: many robots cannot form compatibility with existing workflows and systems
• High costs: upfront expenses and ongoing maintenance needs lack sufficient proof of returns to justify investment. They also deliver lower throughput than polyfunctional robots at a higher price
• Energy constraints: limited battery life means they may not meet the operational time needed for high-mobility tasks.

A more practical approach

Gartner instead points to polyfunctional robots as a stronger alternative.

Polyfunctional robots with wheels and telescopic arms can move boxes, pick cases, scan inventory and perform inspections.

When compared to humanoid robots, these tasks are undertaken faster with less energy consumption.

Polyfunctional robots also have capabilities to enhance efficiency and durability through the integration of new features.

As a result, they could be better suited for fast-paced and demanding supply chain environments, such as warehouses and distribution centres.

“Companies with a high risk appetite and focus on innovation are the best candidates for pursuing humanoid robots at present, given the unproven capabilities of these solutions and related lack of clarity for return on investment,” adds Caleb Thomson, Senior Director Analyst in Gartner’s Supply Chain practice.

“For the majority of companies that will need to prioritise robots that maximise throughput-per-dollar invested, we expect polyfunctional robots to be the superior solution.”

Gartner suggests that leaders make strategic decisions regarding robotics investments, including pursuing pilot programmes to ensure validity.

They should remain open to collaboration with emerging providers to align solutions with operational needs.