BALYO – Retail Distribution Center Goods-to-Person Automation

BALYO implemented a goods-to-person automation system for a major retail distribution operator serving hundreds of stores. The system uses robotic storage units and autonomous carriers to deliver bins of product to ergonomic pick stations, eliminating the need for warehouse workers to walk miles per shift. Each workstation handles up to 400-600 picks per hour, approximately three to four times the rate of manual picking. The solution integrates with the retailer's existing ERP and replenishment systems, automating batch wave planning and fulfillment sequencing. Safety systems include zone-based speed restrictions, physical barriers around high-speed robot zones, and vision-based worker detection. The project significantly improved accuracy to above 99.9%, supported store replenishment across multiple SKU categories, and reduced labor requirements during peak retail seasons.