Exotec’s Skypod System Transforms Manufacturing Efficiency

Auchan Retail Luxembourg has taken a significant step in transforming its logistics operations by implementing Exotec’s Skypod robotic system at its Dudelange warehouse.

The move positions Auchan as the first retailer in Luxembourg to integrate Exotec’s cutting-edge technology, marking a crucial milestone in its strategy to enhance efficiency and maintain a competitive edge in the fast-growing e-commerce market.

As part of the global trend towards automation, Auchan's adoption of the Skypod system highlights a commitment to improving both warehouse productivity and customer service.

With warehouse automation projected to reach US$51.12bn globally by 2030, Auchan’s investment in this technology ensures it stays ahead of the curve, streamlining operations and responding to consumer demands for faster delivery.

Streamlining warehouse operations

The Skypod system deployed at Auchan’s Dudelange warehouse features 37 autonomous robots capable of navigating the warehouse’s towering racks.

These robots can efficiently retrieve items from 15,300 storage bins and deliver them to one of three dedicated picking stations for order assembly. This automation significantly reduces the physical workload on warehouse staff, who previously had to walk long distances and manually retrieve products.

Rémy Malchirand, EVP Sales Western Europe at Exotec, explains the system's impact: “By automating warehouse activities, Auchan has significantly increased the quality and reliability of the order picking process, saving employees from a lot of walking and lifting and significantly improving working conditions.”

Auchan's system processes up to 915 orders per hour, ensuring it can meet the demands of modern e-commerce where customers expect rapid delivery.

With around 160,000 orders prepared annually, the warehouse now serves multiple distribution points across Luxembourg more efficiently than ever.

For local customers, orders can even be ready for pick-up just ten minutes after they are placed, underlining the system's contribution to customer satisfaction.

The Exotec Skypod system also offers several significant advantages for manufacturing operations, enhancing the speed, accuracy and flexibility of parts management and delivery.

As manufacturers increasingly face pressure to optimise operations, reduce costs and meet fluctuating production demands, automation like the Skypod system is becoming crucial.

This system's unique capabilities support key manufacturing needs, from just-in-time delivery to improved space utilisation, making it an essential tool for modern production environments.

Streamlined parts management

One of the standout features of the Skypod system is its ability to streamline the management of parts in a manufacturing setting.

Just-in-time production support is vital in today’s lean manufacturing practices, where excess inventory is discouraged and efficiency is prioritised.

The Skypod system excels here by locating and retrieving small but essential components with a high degree of accuracy, no matter where they are in the warehouse. This quick retrieval reduces inventory holding costs, ensuring that production lines receive the necessary parts precisely when needed, supporting a seamless flow of operations.

For manufacturers relying on kitting, a process where specific parts are grouped together for assembly, the system offers a significant boost in accuracy over manual methods.

Automated picking ensures the correct parts are delivered every time, which reduces errors and avoids costly production delays. This improvement in kitting accuracy leads to smoother assembly processes, boosting overall efficiency on the production floor.

Space optimisation in manufacturing facilities

Space is always at a premium in manufacturing environments and the Skypod system offers a smart solution to maximise its use.

One of its most impressive features is its vertical storage capability, with robots able to climb up to 12 metres. The vertical mobility allows manufacturers to fully utilise warehouse height, freeing up valuable floor space that can be repurposed for other critical operations near production lines. This is especially beneficial in facilities where expanding horizontally isn’t feasible.

Additionally, the system’s compact design means it can be easily integrated into existing brownfield manufacturing facilities with minimal disruption. 

Flexibility for changing production needs

In manufacturing, change is constant.

Product lines evolve, demand fluctuates and operational requirements shift, so the Skypod system’s modular design makes it a highly adaptable tool for these dynamic environments.

Scalability is a key feature: as production demand increases, additional robots can be introduced into the system to handle the higher volume. This modularity ensures that manufacturers can respond quickly to peaks in production without needing to invest in significant infrastructure upgrades.

The system is also built to handle changes in SKU (stock-keeping unit) numbers and structures.

As manufacturers modify product lines or switch to different production models, the Skypod system can easily adapt to these shifts, ensuring continuity in operations. This adaptability is crucial in helping manufacturers stay agile in response to market demands and operational changes.

The Exotec Skypod also significantly reduces downtime, thanks to a 99% guaranteed uptime and minimal charging requirements for the robots.

This means that parts are always available for production, preventing costly interruptions to the production line. The system’s ability to process up to 400 lines per hour further enhances its efficiency, allowing manufacturers to quickly retrieve and deliver parts to where they are needed.

Integrating the Skypod system into manufacturing environments helps create a more responsive, efficient and flexible parts management and delivery system. With its high throughput, accuracy and adaptability, manufacturers can significantly reduce waste, improve production speed and better meet the needs of modern manufacturing practices.

In an age where automation is becoming indispensable in production environments, the Exotec Skypod system stands out as a forward-thinking solution.

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