ABB Optical Improves UPH to over 250+ with LocusBots

"We looked at A-frame automatic dispenses and pick-to-light systems, but space constraints were a factor. One of my colleagues knew someone in the automotive industry that used LocusBots, so we went to see them, and it just made sense for our warehouse.”

Tom Calhoun, Senior Vice President of Operations

ABB Optical

Overview & Challenge

ABB Optical Group is a leading provider of optical products, services, and business solutions in the eye care industry. They operate through three business pillars: ABB Contact Lens, ABB Labs, and ABB Business Solutions.

ABB is focused on the future of eye care professionals, helping them succeed by making practices more efficient and assisting providers to effectively navigate market changes. ABB Optical is headquartered in Coral Springs, Florida and most recently opened a National Logistics Center in Hebron, Kentucky.

At the beginning of the pandemic, the team at ABB Optical struggled with recruiting new associates to perform their manual warehouse processes. They looked at a number of automation solutions to improve their productivity and employee satisfaction while ensuring the right item is picked and packed for customers.

“We looked at A-frame automatic dispenses and pick-to-light systems, but space constraints were a factor,” said Tom Calhoun, Senior Vice President of Operations, ABB Optical. “One of my colleagues knew someone in the automotive industry that used LocusBots, so we went to see them, and it just made sense for our warehouse.”

Quick implementation speed and cost efficiency were also important points of consideration for ABB Optical when selecting an automation solution.

Results

Healthcare company improves picking time with LocusBots

Locus deployed a warehouse execution platform and 114 autonomous mobile robots (AMRs) along with a suite of dashboards and actionable reporting tools at ABB Optical’s warehouses, including its National Logistics Center in Hebron, KY in October of 2022.

The Kentucky warehouse (100,000 square feet and holding 160,000 SKUs) was built with input from Locus Robotics to be a Locus-centric facility down to the aisle width that works best with LocusBots. “Locus Robotics has been a great partner as we make changes, and their help has been beneficial,” stated Calhoun.

In the healthcare industry, it’s crucial to capture lot numbers in real time for compliance. With Locus Robotics, ABB Optical tracks that information and ensures that the right item is picked out of the over 160,000 different SKUs they carry. Before choosing the Locus Solution, ABB Optical had an order accuracy rate of well above 95%. Now, with the LocusBots, the accuracy rate is at 98%.

The warehouse associates at ABB Optical find it easy to work with the LocusBots as the displays are available in multiple languages like English or Spanish. These associates have told Calhoun that they have the easiest position in the warehouse, because the bots are self-explanatory and simple to use. The team plans to implement zone picking, which will enable associates to stay in one area instead of walking throughout the large warehouse.

“The Locus Robotics solution is cost-efficient and provides real-time information on what’s moving and not moving to plan accordingly,” says Calhoun.