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Robots in the process flow / Logistics & Warehousing

E-commerce Fulfillment Center: Inbound to Outbound

Even with sorters and automated storage in place, truck unloading, depalletizing, putaway, picking, sorter induction, truck loading, and returns still rely on people. The big advantage: AMRs, robot arms, and humanoids can be added at today's manual workstations while existing racks and conveyors stay as they are.

21 tasks across 7 steps can move to robots.

Illustration of an e-commerce fulfillment center from truck unloading and depalletizing to putaway, picking, packing, sorting and outbound loading, with robots

Process flow

Select a step to jump to its tasks.

  1. 1Unloading4 tasks
  2. 2Depalletizing2 tasks
  3. 3Inspection
  4. 4Putaway3 tasks
  5. 5Picking5 tasks
  6. 6Packing
  7. 7Sorting3 tasks
  8. 8Loading3 tasks
  9. 9Returns1 task
Robot-ready tasksDedicated equipmentStays with people

Process sources: STOCKCREW「EC物流の基礎知識」（6 工程） / LNEWS 佐川グローバルロジスティクス EC Logi Tokyo（2019-05） / マイナビ 佐川グローバルロジスティクス EC Logi Tokyo 取材（2024-10）

Tasks by step

For each step, the tasks people do today that robots already handle somewhere. Follow the link to candidate robots and proven deployments.

  1. Inbound: truck & container unloading

    Unload floor-loaded cases one by one from the back of the trailer onto a conveyor; palletized freight comes off by forklift.

    Robot-ready

  2. Depalletizing & case induction

    Lift cases one by one off inbound pallets onto the receiving conveyor or automated storage, sorting mixed pallets by SKU as they come down.

    Robot-ready
    • In use in JapanRobot ArmLifting cases off pallets onto a conveyor (mixed loads, no pre-registration)

      ASKUL Logi PARK Yokohama (Jul 2021): one Mujin depalletizing robot replacing manual induction of about 6,000 cases a day. Kyowa Shiko 2nd logistics center (Ehime, Mar 2023): two depalletizers handle 1,000+ cases/hour, lifting shipping capacity by up to 70%.

      Source: ビジネス+IT (2021-07-14) / LOGISTICS TODAY (2023-03-16)

      Candidate robots for this taskPalletizing
    • In use in JapanRobot ArmAutonomous Transport RobotLinking depalletizing, palletizing, and AGV replenishment by SKU to warehouse control

      Nippon Unyu Ota Inter office (Gunma, announced Mar 2026): MujinOS coordinates depalletizing/palletizing robots and AGV replenishment by SKU across 97 products in a parts-supply warehouse (adjacent case: automotive parts).

      Source: LOGISTICS TODAY (2026-03-04)

      Candidate robots for this taskPalletizing

  3. Receiving inspection & registration

    Check outer packaging and quantities and register receipts in the WMS; content checks and dimension/weight capture vary by product.

    People

    Count reconciliation and damage judgment stay with people and WMS terminals; automatic dimensioning is measuring equipment, and no public robot case was confirmed.

  4. Putaway & storage

    Put products into storage racks or bins; in goods-to-person systems the shelves or totes come to the worker.

    Robot-ready

  5. Picking

    Collect items per order from racks or bins, either by walking or with goods-to-person systems; case picks come out of automated storage for packing.

    Robot-ready
    • In use in JapanAutonomous Transport RobotPick-assist AMRs that follow workers, removing walking and searching to raise outbound productivity

      Nippon Express NX Komaki DC (Oct 2025), Rapyuta PA-AMR: outbound productivity about 2.5× in three months (42.9 → 110.8 lines/hour). Nippon Express Shinagawa (Daikin parts, Aug 2020): 10 AMRs. STOCKCREW Sugito Dock (Saitama, Jun 2022): 6 Syrius FlexComet + 4 FlexSwift on subscription.

      Source: LNEWS (2025-10-01) / LNEWS (2020-08-26) / ECのミカタ (2022-06)

      Candidate robots for this taskPicking
    • In use in JapanAutonomous Transport RobotRobots climb 3-D racks to retrieve bins and bring them to picking stations (high-density goods-to-person)

      Yodobashi Camera × Exotec Skypod (announced Dec 2022, multiple warehouses); Exotec also partnered with Fast Retailing in 2019 and had 1,000+ robots running in Japan as of Dec 2022.

      Source: MONOist (2022-12-08)

      Candidate robots for this taskPicking
    • In use in JapanRobot ArmRobot HandPiece picking of consumer goods (suction-plus-finger gripper, no item pre-registration)

      PALTAC RDC Saitama (Sugito, operating from late 2019): Japan's first RightHand Robotics RightPick installation with multiple units; unit count and results not published.

      Source: LOGISTICS TODAY (2019-03-19) / RightHand Robotics 事例

      Application for this taskPicking
    • In use in JapanRobot ArmCase picking the required quantity from pallets out of automated storage (auto-measured dimensions and weight, no master data)

      PALTAC RDC Saitama (Jul 2024): eight Okura Yusoki AI case-picking robots; recognize mixed cases at 99.9%+, eliminating measurement and registration work and human error.

      Source: LOGISTICS TODAY (2024-07-08)

      Application for this taskPicking
    • Proven overseasHumanoidTransferring totes delivered by AMRs onto conveyors (humanoid)

      GXO Logistics fulfillment center for SPANX (US, Jun 2024): Agility Robotics Digit under a multi-year RaaS agreement, moving totes from cobots and AMRs onto conveyors; unit count undisclosed.

      Source: DC Velocity (2024-06-28)

      Application for this taskWarehouse Transport

  6. Packing & labeling

    Box the items with dunnage and the packing slip, seal, and apply the shipping label; in e-commerce the high-mix, small-lot packing is often the bottleneck.

    Equipment

    Handled by automatic packing machines: Carton Wrap at Sagawa Global Logistics EC Logi Tokyo measures the item, cuts the carton, seals it, and applies the label at 800 cases/hour (since Apr 2020). No confirmed robot case for the box-filling itself.

  7. Sorting & induction

    Sort parcels by destination and route; people remain for sorter induction, orienting labels for scanning, and moving the large or irregular items that sorters cannot take.

    Robot-ready
    • In use in JapanAutonomous Transport RobotDestination sorting with small sorting robots, in a compact layout that can be reconfigured

      Sagawa Global Logistics Higashimatsuyama SRC (Saitama, Aug 2021): 35 Plus Automation t-Sort units for 400 destinations; shipping throughput +32%, staff −27%, returns throughput +343%, training time −70%.

      Source: ECのミカタ (2021-08-05)

      Candidate robots for this taskParcel Sorting & Induction
    • In use in JapanAutonomous Transport RobotMoving large and irregular parcels that the sorter cannot take to their destinations by AMR instead of carts

      Sagawa Express X Frontier hub (Koto, Tokyo, Dec 2022): 12 Plus Automation JUC-S800R (1F, up to 800 kg) and 12 LexxPluss Hybrid-AMR (3F); the sorter handles 90% of parcels, and the rest is now automated.

      Source: LNEWS (2022-12-12)

      Candidate robots for this taskWarehouse Transport
    • PoC stageHumanoidGrasping parcels, turning the label face-up, and inducting them one by one onto the conveyor or sorter (humanoid induction)

      Robotera × China Post Shenzhen Longgang hub (on site from Nov 2025, PoC completed May 2026): 100 parcels/hour at first, 1,200/hour by late May 2026, about 90% of a human sorter; partnership with SF Express signed Jan 2026. Figure AI showed Figure 02 moving parcels between conveyors and orienting labels (Feb 2025, customer undisclosed).

      Source: 36Kr (2026-06-03) / Automated Warehouse (2025-02-28)

      Candidate robots for this taskParcel Sorting & Induction

  8. Outbound: palletizing & truck loading

    Stack outbound cases onto pallets or roll cages and load them into trucks; people still decide mixed-load positions and work inside the trailer.

    Robot-ready

  9. Returns processing

    Unpack returned items, judge their condition for resale, disposal, or clearance, repack, and return them to stock; packaging and condition vary, so the work is hard to standardize.

    Robot-ready
    • Proven overseasRobot ArmGrasping, identifying, and sorting returned fashion items (dual-arm robot that handles unseen items)

      CEVA Logistics × Sereact at Zalando fulfillment centers (Greven, Germany and Świebodzin, Poland, announced Oct 2026): dual-arm robots grasp, identify, and sort returns without per-item training, on a RaaS model; unit count and results undisclosed.

      Source: Robotics 24/7 (2026-10-08)

Summary

StepRobot-ready taskStageRobot typeUse-case guide
1. Inbound: truck & container unloadingUnloading mixed cases from trailers and shipping containers onto a conveyorProven overseasRobot ArmAutonomous Transport RobotTruck Loading & Unloading
1. Inbound: truck & container unloadingUnloading import containers and floor-loaded trailers (physical-AI unloader)Proven overseasRobot ArmTruck Loading & Unloading
1. Inbound: truck & container unloadingUnloading robot that docks to an existing telescoping conveyor (cases up to 22 kg, 1,000 cases/hour)Product availableRobot ArmTruck Loading & Unloading
1. Inbound: truck & container unloadingUnloading palletized trucks with autonomous forkliftsIn use in JapanAutonomous Transport RobotWarehouse Transport
2. Depalletizing & case inductionLifting cases off pallets onto a conveyor (mixed loads, no pre-registration)In use in JapanRobot ArmPacking & Palletizing
2. Depalletizing & case inductionLinking depalletizing, palletizing, and AGV replenishment by SKU to warehouse controlIn use in JapanRobot ArmAutonomous Transport RobotPacking & Palletizing
4. Putaway & storageBringing mobile shelves to workstations so staff no longer walk for putaway and picking (shelf-carrying AMRs)In use in JapanAutonomous Transport RobotWarehouse Transport
4. Putaway & storageRobotizing putaway, storage, and picking at a mail-order site handling large items (up to 100×100×200 cm)In use in JapanAutonomous Transport RobotWarehouse Transport
4. Putaway & storageStowing items into the top rows of storage pods and picking from them (arm with tactile sensing)Proven overseasRobot ArmPicking
5. PickingPick-assist AMRs that follow workers, removing walking and searching to raise outbound productivityIn use in JapanAutonomous Transport RobotPicking
5. PickingRobots climb 3-D racks to retrieve bins and bring them to picking stations (high-density goods-to-person)In use in JapanAutonomous Transport RobotPicking
5. PickingPiece picking of consumer goods (suction-plus-finger gripper, no item pre-registration)In use in JapanRobot ArmRobot HandPicking
5. PickingCase picking the required quantity from pallets out of automated storage (auto-measured dimensions and weight, no master data)In use in JapanRobot ArmPicking
5. PickingTransferring totes delivered by AMRs onto conveyors (humanoid)Proven overseasHumanoidWarehouse Transport
7. Sorting & inductionDestination sorting with small sorting robots, in a compact layout that can be reconfiguredIn use in JapanAutonomous Transport RobotSorting & Induction
7. Sorting & inductionMoving large and irregular parcels that the sorter cannot take to their destinations by AMR instead of cartsIn use in JapanAutonomous Transport RobotWarehouse Transport
7. Sorting & inductionGrasping parcels, turning the label face-up, and inducting them one by one onto the conveyor or sorter (humanoid induction)PoC stageHumanoidSorting & Induction
8. Outbound: palletizing & truck loadingPalletizing outbound cases onto pallets, roll cages, and cart racks (stacking positions computed from size and weight)In use in JapanRobot ArmPacking & Palletizing
8. Outbound: palletizing & truck loadingLoading pallets into trucks with autonomous forklifts that cope with truck parking offsetsIn use in JapanAutonomous Transport RobotWarehouse Transport
8. Outbound: palletizing & truck loadingTruck-loading (vanning) robot that stacks cases inside the trailerPoC stageRobot ArmAutonomous Transport RobotTruck Loading & Unloading
9. Returns processingGrasping, identifying, and sorting returned fashion items (dual-arm robot that handles unseen items)Proven overseasRobot ArmSorting & Induction

Before you deploy

  • Load profile: floor-loaded versus palletized freight decides the unloading and loading robot; check case weight limits (about 22 kg for Stretch and TruckBot) and trailer depth.
  • Dock conditions: telescoping conveyor availability, wing-body versus van trucks, and truck parking offsets; autonomous forklifts correct for position, but check the existing dock first.
  • Master data needs: some depalletizing and case-picking systems work master-less by recognizing size and placement; for piece picking, check SKU count and the share of items the robot can handle (about 75% for Vulcan).
  • WMS/WES integration and phasing: shelf AMR fleets have grown from 56 to 216 units, and some sites started on subscription (RaaS); plan peak-season scaling and the WMS changes up front.
  • Items the sorter cannot take: automated sorters handle about 90% of parcels; plan AMR transport or humanoid induction for the large, irregular, and soft remainder, and measure the throughput gap versus people.
  • Start humanoids and physical-AI systems as a PoC: induction and truck loading are still in trials, and one site took months to reach about 90% of human speed; set the evaluation period and KPIs (parcels/hour, interventions) first.

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