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Case Study

How Our AMRs Work Happily with Team of Songge

20250313-172648

Units of AMR

y

ROI

%

Efficiency Improved

+ k

Orders Per Day

Project Overview

Songge Cloud Warehouse is a leading regional logistics provider specializing in cosmetics storage and distribution. Handling 30,000–50,000 orders per day with over 30 frontline pickers, Songge sought an affordable, non-disruptive automation solution to meet its growth target of up to 50,000 orders per day—while reducing labor costs. Additionally, with frequent staff turnover and rising hiring expenses, they needed a way to stabilize the workforce and lower recruitment and training costs.

By deploying 50 AMRs, Songge aimed to boost picking efficiency from 110 to 150 orders per person per hour, cut back on new hires, and realize a 3-year ROI. Crucially, the introduction of AMRs relieved operators of strenuous manual tasks, leading to improved job satisfaction, lower turnover, and reduced management expenses associated with frequent hiring and onboarding.

The Problem

Songge Cloud Warehouse faces mounting pressure to maintain steady growth and premium service while controlling internal costs. Workers endure heavy, repetitive tasks, extended work hours, and frequent overtime, resulting in low morale and high attrition. This not only drove up hiring and training costs but also placed a heavier managerial burden on existing staff. The company needed a scalable automation solution that would alleviate operator workload without risking service disruptions and would help stabilize the workforce to reduce management overhead.

  1. Maintaining Steady Growth and Premium Service
    In a highly competitive environment, many cloud warehouses cut prices to attract customers, but this tactic often undercuts profitability. Differentiated, value-added services are a more sustainable way to build lasting customer relationships.
  2. Optimizing Internal Costs
    Focusing on “revenue only” without streamlining costs erodes long-term margins. Songge needed to improve throughput while reducing headcount and overtime, further mitigating the rising expenses of recruitment and management.
  3. Implementing Flexible Automation
    Any automation solution had to require minimal changes to existing facilities and operations. With a heavy daily workload and tight schedules, Songge couldn’t afford lengthy downtimes or overhauls of warehouse infrastructure.
  4. Operator Workload & Morale
    Workers were unhappy with physically demanding tasks and extended work hours, leading to turnover and additional costs for hiring and training. This also impacted overall morale, pushing management costs upward as the team required frequent oversight and new-employee onboarding.

The Solution

We determined that 50 AMRs were sufficient to achieve a 40% efficiency improvement and accommodate up to 50,000 daily orders, with minimal disruption to existing operations. Moreover, by easing operators’ workload, these autonomous solutions helped improve retention, reduce turnover, and cut management expenses related to hiring and training.

  • AMRs to Handle Heavy Tasks
    Rather than relying on operators for loading, unloading, and transport, the autonomous mobile robots now shoulder much of the physical burden. This reduction in strenuous tasks improves working conditions, helping ensure better morale and team stability.
  • Easing Operator Burden & Reducing Overtime
    By offloading repetitive, physically demanding jobs to AMRs, picking teams can complete tasks more quickly and accurately. This streamlined workflow helps finish daily orders on time—if not earlier—so operators can avoid extended or unpredictable overtime. Higher job satisfaction leads to less turnover, saving costs on recruitment and training.
  • Fast, Incremental Deployment
    AMRs were introduced without halting daytime operations. Maps were created, parameters configured, and systems tested overnight. A phased approach—starting in a smaller picking area and expanding gradually—helped workers adapt to new technology while continuing normal operations.
  • Systems Integration & Process Optimization
    We partnered with Songge’s existing WMS provider to integrate robotic tasks, user management, and data flows. Order grouping, routing, and location optimization enabled faster picking and reduced the managerial burden of constantly supervising manual processes.
Songge-FlexSwift-MAX-Operator
Songge-FlexSwift-MAX-Picking-Wall-Trailer

The FlexSwift MAX AMR uses a picking-wall trailer to efficiently fulfill multiple orders at once, reducing travel and sorting time. Its autonomous navigation and lifting system ease operator strain and improve order accuracy and speed.

Songge-FlexSwift-MAX-Queue-Up

FlexSwift MAX AMRs efficiently line up and move autonomously, towing trailers with organized compartments for orders. This system reduces travel time and workload, boosting throughput and accuracy while keeping the warehouse clean and efficient.

Configuration Details

Software
  • HandyPage and SpeedPicker – Mobile applications for real-time picking and task management.
  • megacosmOS GoGoReady – The AMRs’ core operating system ensuring safe navigation and job execution.
System Integration
  • FlexGalaxy.AI – Central orchestration platform for AMRs, devices, users, and task allocation.
  • Wangdiantong WMS – Existing warehouse management system integrated for real-time order processing.
Hardware
  • FlexSwift MAX AMR – Autonomous mobile robots equipped with modular lifting systems.
  • FlexTrailor – Multi-slot cart trailers designed for simultaneous pick-and-sort operations; each slot corresponds to a specific order or customer.

The Results

After a month-long deployment and testing period, the AMR system exceeded its 40% efficiency improvement goal and passed final acceptance:

  • Enhanced Customer Confidence Songge showcased its automation capabilities to clients, demonstrating high-volume, on-time fulfillment with fewer errors and disruptions.
  • Reduced Labor Costs and Lower Turnover A 40% boost in picking efficiency not only lowered staffing requirements by over 10 positions but also eased physical demands on existing workers. This stability reduced turnover, along with the associated hiring and training costs.
  • Improved Team Morale & Less Overtime Because AMRs handle the bulk of heavy lifting and repetitive tasks, operator fatigue has decreased, and overtime has been reduced. Workers are happier, morale is higher, and new-hire onboarding needs have dropped—further controlling management overhead.
  • No Disruption to Operations AMR implementation required no building renovations and zero downtime. Existing workers were trained in stages, and daily fulfillment proceeded without interruption.

Where are we now

Songge’s success shows that AMR technology improves efficiency, cuts costs, and keeps the workforce stable without causing disruptions.

We continue to support Songge Cloud Warehouse in maintaining and expanding its AMR fleet. Since achieving the initial 40% efficiency increase, our ongoing collaboration includes:

  • Ongoing Performance Monitoring
    We provide continuous system evaluations and updates to ensure AMRs and software remain optimized for evolving operational demands.
  • Further Process Improvements
    Data insights gathered from live operations guide incremental enhancements in slotting, routing, and task assignment, helping maintain high morale and stability in the workforce.
  • Additional Warehousing Plans
    As Songge expands into new facilities, we assist with planning and setup to maximize AMR usage. This approach prevents large-scale renovations, keeps labor costs down, and helps maintain a consistent level of service across multiple sites.
  • Shared Success & Promotion
    Songge frequently highlights the automation success story to current and prospective clients, boosting its reputation as a dependable, tech-forward provider. This, in turn, underscores our role in driving value and advancing warehouse innovation.

Songge Cloud Warehousing

Services we provided:

  • Simulation and Analysis
  • AMR Deployment
  • Trailer Customization
  • System Integration