AI-driven robotic order preparation for e-commerce logistics

In the e-commerce and intralogistics industry, companies integrate advanced AI-based collaborative robotics to optimize order fulfillment and adapt to highly variable product flows.

Activity and operational challenges
Decathlon operates extensive e-commerce fulfillment and warehouse logistics environments characterized by high product variability and supply chain fluctuations. The operational challenges included managing the picking, handling, and palletizing of heterogeneous objects with varying shapes, weights, and materials. Furthermore, the facility needed to transition toward a flexible, human-centric production system that could quickly reconfigure operations while reducing the physical strain on warehouse workers.

Improvement objectives
The primary goal, driven by the European MASTERLY project, was to accelerate the transition from traditional mass production to a highly flexible, customized manufacturing system. Management aimed to automate complex order preparation tasks, improve workplace ergonomics, and increase operational flexibility without compromising constant productivity and reliability. A key objective was establishing smooth, safe interaction between human operators and automated processes.

Selected technical solution
To meet these requirements, Comau engineered and validated a smart robotic order preparation system. The solution integrates the MyCo collaborative robot operated via an ROS2-based software architecture. It features advanced sensors, AI-based vision for object recognition, digital twin capabilities, and workflow orchestration tools. An advanced modular gripper enables the autonomous manipulation of rigid, soft, and porous materials commonly found in e-commerce fulfillment centers.

Deployment and support
The system was tested and validated directly within Decathlon's operational logistics environment as part of the final demonstrative activities of the MASTERLY project. The implementation was a collaborative effort involving Comau, Decathlon, and the Genoa-based system integrator STAM, alongside the broader MASTERLY consortium. The parameters for the system were defined by Decathlon's specific operational requirements in the affected order fulfillment process, ensuring the technology addressed real-world challenges.




Quantifiable results
The deployment successfully enables the autonomous handling of diverse materials, securing real-time process optimization. By combining intelligent robotics with digital technologies, the solution ensures continuous operational reliability and scalability. The system effectively enhances workplace ergonomics by reducing physical effort for operators while maintaining high flexibility to adapt to changing production and market demands.

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.comau.com