The Rise of Goods-to-Person Systems in Warehouse Automation

In the early days of online shopping, waiting for a package felt like waiting for a postcard from the other side of the world. Shipping was slow, international logistics were a mess, and warehouses just weren’t built for speed.

Then came the 1990s. Companies needed to move orders faster, so they rolled out the first goods-to-person systems—which laid the foundation for modern-day, fully automated storage and retrieval systems.

What Are Goods-to-Person (GTP) Warehouse Automation Systems?

Instead of workers trekking through endless aisles to locate and retrieve items, person-to-goods (PTG) and goods-to-person (G2P) systems bring inventory straight to workers at ergonomic picking stations.

Here’s how it works: An order comes in, automated systems pull the items from storage and send them to a picking station. The worker picks the items, confirms the order, and sends it off for packing and shipping. No unnecessary walking, no wasted time.

To work smoothly, G2P systems use specialized racking systems, vertical lift modules, or fully automated storage and retrieval systems (AS/RS). They also easily integrate with other warehouse technology, such as pick-to-light systems, warehouse management software, takeaway conveyors, or robotic arms for piece picking.

G2P systems can be found in distribution centers moving goods to pick-and-pack stations, manufacturing lines delivering raw materials or parts, and e-commerce fulfillment centers—making order picking faster and more accurate.

G2P systems rely on a variety of cutting-edge technologies to function effectively. Here are some of them:

1. Automated Storage and Retrieval systems (AS/RS): These systems use cranes or shuttles to move items in and out of packed storage to save space and speed up retrieval
2. Voice-directed picking: This technology provides audio instructions to show workers which items to pick, keeping their hands free and making the process faster.
3. Robotic shuttles: These self-driving bots navigate through aisles, grab bins or totes, and drop them off at picking stations.
4. Pick-to-light and put-to-light systems: These systems use LED displays to show workers exactly what to grab or where to place items, thereby reducing mistakes.
5. Automated guided vehicles (AGVs): These warehouse robots autonomously handle the heavy lifting and movement of pallets and large items.

Types of Goods-to-Person Systems

Automated storage and retrieval systems (AS/RS) 

 AS/RS systems use conveyors and elevators to move products straight to picking stations. They’re built for tall storage spaces up to 40 ft and dedicated travel paths to maximize vertical space. These systems are best used in environments where minimizing human interaction is crucial—think freezers or high-density warehouses. Since AS/RS handles retrieval independently, it reduces workers’ exposure to harsh conditions and cuts down on unnecessary walking.

An added benefit is that they improve product security by protecting from theft, damage, and unauthorized access. This is especially useful for distributors who deal with high-value inventory.

AS/RS systems aren’t the usual plug-and-play warehouse solutions. They require careful planning to function effectively, and they have limitations on the size of products and the deployment times they can handle.

Autonomous Mobile Robots (AMRs)

AMRs are designed to move freely within the same workspace as workers, following them, meeting them at designated points, or shuttling goods between locations. In addition to transporting goods, AMRs can also handle various tasks like sorting, scanning, inventory tracking, and assisting with packaging or assembly.

AMRs use sensors and AI to freely navigate obstacles and reroute as needed. Some function as  Automated Guided Vehicles (AGVs), a type of automated storage and retrieval system that follows fixed paths guided by magnetic tape, laser beams, or floor markers.

AGVs are a good choice when products are too big to be carried by AS/RS systems or when companies need a quick tech upgrade. By cutting out human and forklift slowdowns, AMRs keep fulfillment moving fast and workflows running smoothly.

Carousel Systems

Carousel systems use rotating shelves and bins as warehouse conveying equipment to deliver products to a fixed packing station. They work best for operations handling lots of small to medium-sized items. In particular, they are perfect for optimizing vertical space in tight environments.

Carousels come in two types: horizontal and vertical. They’re powered by automated software that spins goods to the right position where workers get what they need fast.

The right goods-to-person system depends on your warehouse’s needs. You can mix more than one GTP system. For instance, You can combine both AS/RS and AMR technologies. AS/RS can fetch products and pass them to a worker, who sorts them into outbound orders. Once the pallet is ready, AMRs move it to a staging area and onto a conveyor for wrapping and shipping.

Benefits of Implementing GTP Systems

The benefits of a GTP system fall into two categories: human operations and warehouse operations.

Benefits for Human Operations

• Increased efficiency and productivity: GTP systems handle order fulfillment automatically. No more manual picking, no more wasted time. Workers can get products faster with fewer mistakes.
• Lower labor costs: Robots and automated systems do the heavy lifting, so workers spend fewer hours on repetitive tasks, resulting in a leaner workforce and lower costs.
• Reduced human errors: Wrong picks lead to wrong shipments, but GTP systems fix that by automating the process. Smart tech solutions like RFID keep data entry spot-on, so errors don’t pile up.
• Increased scalability: Peak seasons can be chaotic, but GTP systems can seamlessly handle surges, keeping orders moving and mistakes in check.
• Ergonomic and comfortable work environment: GTP systems allow operators to remain stationary while the system delivers products to them, creating a smoother, more comfortable workflow.

Benefits for Warehouse Operations

• Real-time inventory visibility: GTP systems use smart software and sensors to track inventory in real time, so there’s no more guessing. You’ll know what’s in stock, what’s moving, and what’s about to expire, making restocking effortless.
• Accurate data-generated decisions: Some GTP systems, like TGW Logistics’  FlashPick, don’t just store products—they predict demand. With accurate data, you can optimize inventory levels and keep your supply chain running smoothly.
• Optimize storage space: GTP systems work in tight spaces and reach high shelves, eliminating the need for wide aisles and walkways. That means more room for inventory and better use of every square foot.

Key Challenges in GTP System Implementation

While GTP systems come with significant advantages, rolling them out isn’t always smooth sailing.

• High implementation cost: Robotic equipment, storage racks, and advanced software are expensive. Add installation and maintenance, and the price tag gets even steeper.
• Inadequate system integration: Integrating GTP with your warehouse management system (WMS) can be a headache. Legacy WMS setups often struggle with real-time data exchange, leading to inventory errors and operational slowdowns.
• Change management: New systems disrupt routines, so employees might worry about job security or struggle with unfamiliar tech. Training is key—not just to boost adoption but also to prevent injuries from mishandling new equipment.
• Data security and management: GTP systems handle sensitive inventory and operations data, making them targets for cyber threats. To keep your system locked down and your data safe, you need to implement strong encryption, firewalls, and strict access controls.

Wrapping it Up

GTP systems have revolutionized warehouse automation. Orders are picked faster, accuracy increases, and workers don’t waste time walking back and forth. They maximize storage space and enhance real-time inventory tracking. Whether you choose AS/RS for dense storage, AMRs for flexible movement, or carousels for compact setups, goods-to-person systems generally boost efficiency and cut operational costs.