Making Automation Real for Existing Warehouses

The Challenge of Automation for Existing Warehouses

In the automation space, newly built, automation-first facilities tend to get all of the attention. These facilities are designed with smooth floors, strategically placed pillars, and other infrastructure elements primed for seamless integration with robotics and other technology. The process of implementing automation in these facilities is relatively straightforward because they were designed to be automated.

Cartesian Kinetics, a bronze-level OEM member of the Rockwell Automation Partner Network, recognized a reality that automation leaders have not addressed. These new builds represent only a fraction of the distribution and fulfillment centers in operation today. Across the U.S., more than 25,000 warehouses were built decades ago and operate successfully, but do not have the infrastructure requirements for modern automation. In fact, they have infrastructure that makes implementing automation a challenge—uneven floors, manual racking systems, and deeply ingrained operational workflows.

For warehouse operators running older facilities, “automating processes feels akin to changing a tire while the car is moving,” says Cartesian Kinetics cofounder and CEO Jayendran Balasubramanian. They must maintain daily operations while contending with hurdles that inhibit the straightforward adoption of robotics.

Additionally, logistics and fulfillment workflows are inherently unpredictable, unlike the steady cadence of manufacturing. Fulfillment operators face difficulties trusting that automation can handle the random nature of orders and deliveries and improve productivity.

At the same time, increasing e-commerce demand and consumer expectations for faster fulfillment are driving the need for automation like never before. Operators face the dual challenge of staying competitive while addressing the unique constraints of their facilities.

Modernizing Existing Warehouses with a Tailored Automation Solution

Cartesian Kinetics worked with Rockwell Automation to develop solutions that integrate into existing warehouses and enhance human-machine collaboration. One of the key technologies deployed was Emulate3D™ Digital Twin Software. Emulate3D™ digital twin software allows Cartesian Kinetics to create virtual replicas of warehouse operations, enabling customers to simulate real-world scenarios and predict the impact of various factors, such as peak shopping days or supply chain disruptions. This technology has been instrumental in helping customers test and refine solutions before investing in physical hardware, reducing risk and cost.

Cartesian Kinetics also adopted Rockwell Automation Independent Cart Technology (ICT). Unlike robotics that rely on wheels, ICT leverages magnetic levitation for precise movement. This design allows automation systems to navigate existing racking systems, no matter how imperfect, removing the need for costly and disruptive infrastructure overhauls.

The company’s use of ICT prioritizes human productivity. Robots now deliver multiple bins to stationary workers, enabling them to process orders more efficiently. This “goods to person” approach reduces worker fatigue and cognitive load, creating smoother operations and lessening errors.