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Future-proof and high-performance

26.08.2025

The intralogistics of the future.

As early as 2006, Angela Merkel remarked: »Whoever knows how to successfully respond to demographic change, I congratulate them!« This statement is more relevant today than ever before. The logistics industry, in particular, is feeling the intense impact of demographic change. The ongoing shortage of skilled workers and continuous growth are presenting companies with enormous challenges. Added to this are rising customer expectations for shorter delivery times combined with smaller order quantities – a combination that significantly increases the demands on logistics. Many companies are responding to these challenges with increased use of automation and artificial intelligence (AI). But in light of the multitude of available technologies, one question arises: which solutions offer real long-term value?

»The shortage of skilled workers, rising energy costs and considerable bureaucratic hurdles are forcing companies to find new ways to secure their competitiveness,« explains Johann Zrenner, Managing Director of IGZ.

Against this backdrop, companies face fundamental strategic decisions: Should they increasingly rely on outsourcing and relocating processes abroad, or invest in innovative automation technologies to maintain their market position? Especially in order picking and internal material flows, modern robotics solutions have already proven how they can take logistics processes to the next level. Technologies such as »Pick by Robot« and »Move by Robots« from IGZ demonstrably increase efficiency and offer effective solutions for challenges in traditionally manual work areas. In addition, AI and intelligent warehouse strategies, such as IGZ Smart Slotting, make it possible to tap unused potential in warehouses more efficiently.

Pick by Robot: The Future of Order Picking

The bilstein group in Gelsenkirchen has already successfully initiated the transformation: Since October 2022, two modern picking robots (LUKE) have been operating in small-parts picking at the new logistics center. These robots work hand in hand with traditional »goods-to-person« workstations, taking over order-related picking, the consolidation of items in totes, and tote splitting — resulting in a noticeable improvement in storage utilization.

Thanks to direct integration into SAP EWM/MFS, the robots can be connected without additional middleware and achieve an availability rate of over 98%. Especially in multi-shift operations, the scalable plug-and-play solution demonstrates its cost-effectiveness and enables additional robots to be flexibly retrofitted at appropriately configured picking stations when required. The sanitary manufacturer Geberit in Pfullendorf benefits from this flexible retrofit capability in its existing logistics center — within just two weeks, LUKE was put into operation on the existing conveyor system. Now, humans and machines work side by side, demonstrating how quickly innovative technologies can be implemented into existing processes to create sustainable value.

Thanks to machine learning, LUKE continuously optimizes processes, including automated master data maintenance. AI-based image recognition ensures high picking quality through precise camera-based verification, which in turn increases efficiency across the entire logistics network. The patented IGZ Rotary Gripper enables automated gripper changes within seconds, allowing LUKE to handle a wide range of items. The fourth generation of the IGZ robotics solution also performs additional functions such as automatic labeling and 100% quality checks. Optimized packing algorithms further maximize tote utilization, contributing to the reduction of the CO2 footprint.

Felix Wortmann, Project Manager at the bilstein group, emphasizes: »Through seamless integration and continuous optimization with LUKE, we reduce employee workload while being perfectly prepared for future customer requirements.«

Move by Robots: Autonomous Transport Solution for Efficient Logistics

Not only in order picking, but also in the transportation of goods, robotics solutions offer clear advantages. Move by Robots from IGZ optimizes autonomous goods transport directly from SAP EWM/MFS, entirely without subsystems. It enables the integration and control of vehicles from various manufacturers directly in SAP EWM/MFS in accordance with the VDA 5050 standard, making logistics more flexible, efficient, and cost-effective. Additional subsystems and extra visualization tools are eliminated. Thanks to AI-supported optimization of transport routes, the best possible route is always selected, and through integration within EWM/MFS, transports are perfectly synchronized with conveyor system flows. This not only increases efficiency but also reduces CO2 emissions by up to 20%. As a result, vehicle requirements are significantly lowered, ensuring near-continuous material flow availability. In addition, employees are relieved from repetitive tasks, which greatly improves working conditions.

Smart Slotting: Intelligent Storage Location Assignment for Optimal Inventory Management

In addition to activities on the warehouse floor, the storage area often holds untapped potential for optimizing intralogistics performance. The IGZ Best Practice Smart Slotting uses AI technology to dynamically classify storage zones based on historical data such as turnover rates. Smart Slotting determines the optimal zone and ideal storage location for each inbound item. This significantly shortens the travel paths of stacker cranes for storage and retrieval, while simultaneously reducing wear and tear as well as energy consumption. IGZ Smart Slotting can be retrofitted, increasing the storage and retrieval performance of existing warehouse technology by up to 20%.

Since 2024, the bilstein group in Gelsenkirchen has benefited from the intelligent allocation of storage locations based on Smart Slotting. Felix Wortmann, Project Manager at the bilstein group, summarizes the results:

»Since March, Smart Slotting has reduced the travel distance of our stacker cranes in our automated high-bay warehouse by about 20% — that corresponds to roughly 6,000 km. To put it in perspective: that’s the straight-line distance from Gelsenkirchen to New York City.«

Conclusion: Flexibility and Sustainability Through Automation

The logistics industry faces major challenges that require innovative solutions to maintain competitiveness. The use of automation technologies and artificial intelligence (AI) such as Pick by Robot and Move by Robots enables companies to make their processes more efficient and flexible. Successful implementations at companies such as the bilstein group, Geberit, and many other customers demonstrate how seamless integration into SAP EWM/MFS not only increases efficiency but also improves the flexibility and sustainability of logistics processes.

These technologies are not only a response to the shortage of skilled workers but also enable companies to position themselves for long-term success. The flexible and cost-effective scalability of robots and autonomous vehicles helps optimize processes while relieving employees of repetitive tasks — a key advantage, especially in times of labor shortages.

Through continuous development and the integration of machine learning and AI-based process optimization, companies remain capable of meeting future demands. Automating picking and transport not only improves efficiency but also contributes to reducing the CO2 footprint — an essential step toward the logistics of the future.