Increased storage density, Optimization, and Labor Cost Savings by integrating AMR’s and AS/RS with Geek+

The Client

A global leading manufacturer of heavy-duty power tools, hand tools, and accessories for professional and DIY users worldwide. Known for their relentless focus on innovation, durability, and performance, the company serves tradespeople in construction, manufacturing, maintenance, and utilities. With a commitment to jobsite solutions, they continue to redefine industry standards through advanced cordless technology, smart tools, and productivity-driven systems. 

Challenge: Labor Shortages and Warehouse Capacity Constraints

Approaching peak season, the manufacturer faced significant warehouse challenges—including a shortage of forklift operators and insufficient storage space. Their traditional warehousing model, reliant on static racking systems and manual forklift operations, was becoming unsustainable. To scale operations without leasing additional warehouse space or hiring more workers, the company sought a long-term warehouse automation solution to improve labor efficiency and maximize storage capacity. 

Solution: Goods-to-Person Automation with Geek+ and BlueSkye Automation

To meet their operational goals, the client partnered BlueSkye Automation and Geek+ to deploy a SkyCube pallet-to-person system at their Mississippi distribution center. This unique to the industry solution integrates a four-way shuttle automated storage and retrieval system (ASRS) to maximize vertical storage space together with a ground level autonomous mobile robot (AMR) shelf–to–person system to maximize picking efficiency in a hybrid configuration: 

• Inbound pallets are transported by AMRs to vertical elevators and into high-density storage racks.
• Inside the racks, the four-way shuttles place pallets into optimal storage locations and retrieve pallets to replenish ground-level forward picking zones.
• The ground-level AMRs retrieve shelves and pallets from the forward pick zone to deliver orders directly to picking workstations.
• Through integration with an existing Warehouse Management System (WMS), the system automatically replenishes materials for outbound orders thereby streamlining speed, safety, and labor savings.