Automated Storage & Retrieval Systems for Distribution Center Fulfillment

NAPA Auto Parts selected Hai Robotics and Hy-Tek Intralogistics to engineer and deploy an automated fulfillment architecture across its distribution flow center operations. The industrial cooperation integrates autonomous case-handling mobile robots with existing facility layouts to support high-density inventory buffering, rapid SKU picking, and scalable order consolidation.

Fulfillment Challenges in Automotive Aftermarket Distribution
Automotive aftermarket parts distribution involves handling hundreds of thousands of distinct item dimensions, varying turnover rates, and inconsistent packaging formats. Manual picking operations in these environments encounter throughput bottlenecks, floor space constraints, and high labor overhead during peak order cycles.

To overcome these layout and handling limitations, NAPA required a flexible materials handling framework capable of consolidating vertical cubic storage while maintaining high pick accuracy. The system requires dynamic integration between warehouse management software, physical picking stations, and autonomous robotic transport units.

System Architecture and Partner Responsibilities
The deployment centers on the HaiPick automated storage and retrieval system developed by Hai Robotics, integrated under an end-to-end material handling architecture designed by Hy-Tek Intralogistics.

Hai Robotics supplies the multi-robot fleet, vertical racking structures, and standard case-handling mechanisms. These autonomous robots navigate dedicated storage grids using visual or inertial positioning, retrieving standardized storage totes and delivering them directly to ergonomic picking stations.

Hy-Tek Intralogistics acts as the prime systems integrator. The firm is responsible for facility engineering, controls architecture, host enterprise software interfacing, and end-to-end commissioning. Prior to full-scale deployment, Hy-Tek utilized its internal facility to test live picking cycles, cycle times, and kinematic flow configurations under simulated operational loads.

Operational Validation and Facility Deployment
Deployment phases prioritized kinematic validation, pallet-to-tote decanting flows, and pick-to-light replenishment interfaces. Testing at the integration facility allowed engineering teams to verify robot acceleration, turning envelopes, and multi-robot dispatching rules before physical site installation.

The automation architecture connects directly into NAPA's enterprise resource planning and warehouse execution software via standard industrial communication protocols, coordinating inventory allocation without disrupting parallel outbound shipping schedules.

Target Applications and Throughput Impact
The primary application domain covers discrete piece picking, broken-case fulfillment, and replenishment buffering in industrial and automotive component distribution centers.

By converting floor footprints into vertical multi-tier tote storage, the robotic installation increases cubic storage density and eliminates travel time for warehouse operators. The synchronized dispatching algorithms ensure predictable cycle times for critical aftermarket fulfillment pipelines.

Edited by Natania Lyngdoh, Induportals editor, with AI assistance.

www.hairobotics.com