Geek Plus, one of the leading warehouse automation companies globally, has played a pivotal role in transforming Siemens’ Shanghai facility. Their innovative robotic system has resulted in a remarkable 300 percent increase in storage capacity, a 150 percent boost in picking efficiency, and an accuracy rate soaring to 99.99 percent.
The partnership between Geek+ and Shanghai Siemens Switchgear has blossomed over five years of collaboration, characterized by ongoing innovation and an eagerness to push boundaries. Recently, they achieved a monumental milestone by establishing what they claim to be “the world’s first robot-driven intelligent warehouse in the discrete-manufacturing sector.” This facility encompasses the entire process, from receiving and shelving to storage, picking, and distribution, setting a new benchmark for lean digitalization in the industry.
Winning the Future by Acting Early
According to Shu Changhong, CFO of the Electrical and Automation Division at Siemens (China), “To win the future, you must not only think far ahead, you must act early.” This foresight has been crucial in spearheading the partnership that has led to groundbreaking advancements in warehouse automation.
Since their collaboration began in 2019, Geek+ and Siemens have navigated numerous difficulties, including the absence of ready-made reference solutions and the challenge of maintaining uninterrupted production while implementing innovative changes. Their efforts resulted in a comprehensive automated material-handling system that caters specifically to discrete manufacturing needs.
From Retrofit Automation to Lean Digitalization
Siemens’ Shanghai facility, a core element of its global supply chain, specializes in medium-voltage switchgear production, managing a complex inventory of hundreds of thousands of SKUs — from substantial steel structures to tiny electronic components. Traditional manual operations were unable to keep pace with the demands for customization and rapid market reactions.
To address these challenges, Geek+ and Siemens embarked on a three-phase upgrade initiative beginning in 2019. This included an initial deployment of automation technologies, followed by deeper system integration, and culminating in full-process digitalization. These enhancements paved the way for lights-out operations and established a reusable smart-logistics model tailored for the discrete-manufacturing sector.
Robot Army and Systems Revolution
The heart of the intelligent logistics system developed by Geek+ for Siemens is its “robot army,” consisting of over 100 units of varying types. Underpinning this system is an AI-driven intelligent scheduling mechanism. Various specialized robots — such as the shelf-picking robot P800, the tote-picking robot RS8, and the small-tote handling robot P40 — work collaboratively to provide seamless connectivity across the entire process, from receiving and quality inspections to shelving, storage, picking, and production-line feeding.
Digitally Coordinated Ecosystem
Geek+ took the initiative to integrate its fleet of robots with Siemens’ Warehouse Management System (WMS), Manufacturing Execution System (MES), and SAP systems, thereby creating an intelligent, collaborative ecosystem that spans the entire supply chain. This real-time data exchange facilitates Just-In-Time (JIT) replenishments, improves routing through Plan for Every Part (PFEP) strategies, and enhances inventory visibility, significantly improving turnover and timeliness.
The integration not only translates production demand into precise material deliveries but also minimizes human error and enhances delivery accuracy, making the entire operation more efficient.
Intelligent Zoning and a Spatial Revolution
In an effort to optimize the storage process in a multi-SKU environment, the project successfully implemented intelligent zoning, dynamically assigning storage areas based on the sizes and handling needs of different materials. Small items are housed in a 6.9-meter small-parts mezzanine accessed by tote robots, while medium-sized parts are stored in four-way shuttle racks. Larger or irregular items are arranged on elevated steel platforms, efficiently managed by shelf robots.
These smart spatial adjustments resulted in a remarkable 60 percent reduction in the footprint for small parts and an astounding 300 percent increase in overall storage capacity—within the same space.
Human-Centered Safety and Upskilling
Safety has been a paramount concern for Shanghai Siemens in this project, which exemplifies the successful integration of human and machine efforts facilitated by Geek+. Key safety measures include:
- Site-wide physical protection: The implementation of an intelligent safety-fencing system around robot operation zones ensures safe operations in unmanned scenarios.
- Professional safety workwear: Special workwear has been developed that, alongside the robots’ intelligent obstacle-avoidance systems, provides dual protection for staff entering robot operational areas for maintenance or handling unexpected situations.
- Innovative interaction mechanisms: A safety traffic-light system in the production-line feeding area ensures organized and safe human-machine interactions, highlighting the emphasis on thoughtful integration during intelligent transformation.
Additionally, the project has facilitated ergonomic improvements, enhancing workplace comfort. Warehouse employees have shifted from physically demanding roles to more technical positions, with one individual commenting, “Through this project, I transformed from a receiving worker to a systems operations and maintenance engineer, becoming a technical backbone of the team and gaining exposure to advanced technologies.”
Results and Future Direction
Aiming for continuous improvement, Dai Lijun, General Manager at Shanghai Siemens Switchgear, notes that the partnership will persist in expanding their collaboration. By advancing full-process intelligent upgrades and leveraging lean digitalization, they aim to build a smart-logistics ecosystem powered by big data and AI, enhancing production efficiency and flexibility.
This commitment to technology integration, coupled with a focus on employee development, strives to create a digital factory that harmonizes technology and humanistic care, offering a template for the broader manufacturing industry’s transition into an era defined by digital intelligence.