Distribution centre moves 40% more stock per shift with KettyBot
A regional distribution centre integrated KettyBot into its picking workflow. Robots carry picked items to packing stations, letting pickers stay in the aisles.
Client
Distribution operator (Midlands)
Location
Midlands
Robot
KettyBot
The challenge
Pickers were spending nearly a third of every shift walking finished totes to the packing line. Throughput plateaued well below the site's stated capacity, and overtime spend was creeping up.
Our approach
Mapped the main aisles and packing stations with the Keenon team.
Configured KettyBot to shuttle filled totes from drop-points to pack.
Trained the floor team — running before-and-after shift comparisons for the first fortnight.
Reviewed the route weekly for the first quarter to capture incremental wins.
Outcomes
40% increase in items moved per shift across the trial period.
Picker productivity up 25% on the same headcount.
Overtime spend down sharply in month two and beyond.
Payback period: 11 months.
"Our pickers stay in the aisles, the robots move the totes — the bottleneck moved off the floor entirely."
— Operations Director, Distribution operator (Midlands)
Could this work in your operation?
A free site visit takes a couple of hours and tells you exactly what's possible.
