Lets Meet Shelfbot

Year

2022

Location

Melbourne, Australia

Company Size

15+ Employees

Before selling Shelfbot to customers, we proved it works by using it ourselves: kitting and assembling our own robots with the same Goods-to-Person system we sell.

Quick Facts

Metric	Value
Industry	Robotics Manufacturing
Use case	Kitting & assembly
Parts tracked	500+ unique components
Major assemblies	Platform, Top Car, Mast, Station, Controller, Rails
Complexity	Multi-level BOMs with mechanical, electrical, and structural parts

Challenge

Building automated warehouse robots is complex. Each Shelfbot system contains hundreds of components across multiple assemblies:

Manufacturing Challenges:

Complex BOMs: Each robot requires precise kitting of mechanical parts, electronics, cables, fasteners, and structural components
Assembly accuracy: Wrong parts or missing components cause costly delays, rework, and long-term robot reliability issues
Inventory tracking: Managing stock across hundreds of SKUs (pulleys, motors, sensors, profiles, screws, PCBs)
Assembly sequence: Parts must be available in the right order for efficient build sequences
Quality control: Scan-confirmed picking ensures correct components in each kit

Major Assemblies to Kit:

Platform (motors, pulleys, belts, sensors, PCBs, wheels, rails)
Top Car (controller, drag chains, power distribution, cables)
Mast (structural profiles, mounting hardware, guards)
Station (cabinet, door, e-stop, trolley, printer integration)
Rails & mounting hardware
Server & control systems

Manual kitting with paper pick lists was error-prone and slow. Parts were scattered across the workshop, creating excessive travel time for assembly technicians.

Solution

We deployed Shelfbot in our own manufacturing facility to solve our kitting problem:

System Configuration:

Bins storing components: Mechanical parts, electronics, fasteners, cables organised in standardised bins
BOM app integration: Custom Bill of Materials application integrates with Shelfbot via API to track requirements for each assembly
Kitting workflow: BOM generates pick lists → Shelfbot presents bins → scan-confirmed picking → completed kit ready for assembly
Assembly stations: Fixed work areas where kitted parts arrive for robot assembly

How It Works:

BOM planning: Each robot configuration has a detailed BOM tracking every component needed
Pick list generation: BOM app creates pick lists for each assembly kit
Goods-to-Person picking: Shelfbot retrieves bins containing required parts
Scan confirmation: Barcode scanning ensures correct part and quantity
Complete kits: Assembled kits delivered to build stations with all parts verified

Parts Categories:

Mechanical: Pulleys (5M various sizes), belts, aluminum profiles (2060, 4080), hollow sections (80x40, 100x50)
Fasteners: Screws (#4-40, 10G, 6G, 8G in various lengths), mounting hardware
Electrical: Motors, sensors (HG-30B), PSU (24V LRS-350-24), controllers, PCBs
Structural: Rails, tracks, angles, mounting plates, drag chains
Assemblies: Pre-built subassemblies stored in larger bins

Results

Using Shelfbot to build Shelfbot delivered measurable improvements:

Operational Benefits:

Faster kitting: Eliminated technician travel time searching for parts across workshop
Fewer errors: Scan-confirmed picking caught wrong parts before they reached assembly
Better inventory visibility: Real-time stock tracking through BOM app integration
Consistent quality: Every kit verified complete before assembly starts
Scalable process: Can kit multiple robots simultaneously without confusion

Manufacturing Insights:

Assembly time reduced: Technicians start with verified complete kits instead of hunting parts
Rework eliminated: Wrong parts caught at picking stage, not during assembly
Stock-outs prevented: System alerts when components running low for upcoming builds
Training simplified: New technicians follow scan-guided process for picking

Strategic Value:

Proof of concept: Demonstrates manufacturing/kitting use case to prospective customers
Product validation: We use our own system daily, exposing any operational issues
Customer confidence: “We build our robots with it” is a powerful sales message
Use case expansion: Proves Shelfbot works beyond e-commerce/3PL into manufacturing

Why This Matters

Using Our Own System:

If Shelfbot works for building robots (complex, multi-level BOMs), it works for customer operations
We experience the same workflow our customers will use
Product improvements come from real operational feedback
Sales conversations backed by genuine internal experience

Manufacturing Use Case:

Demonstrates applicability beyond traditional warehousing
Shows system handles complex kitting requirements
Proves barcode workflow catches errors in technical assembly
Validates modular approach for various industries

Operational Clarity:

Same simple workflow: request parts → bins present → scan confirm → return bins
Works for 100s of small fasteners and large assemblies alike
Scales from single kit to multiple simultaneous builds

Technology

Goods-to-Person ASRS on AS4084 compliant racking
Standardised bins (720 × 420 × 285 mm) storing components
Custom BOM tracking application integrated via API
Barcode-guided pick confirmation for every component
Multi-level BOM support (assemblies containing sub-assemblies)
Real-time inventory sync between BOM app and Shelfbot
Category 3 PL d safety architecture
Fixed pick stations for kitting operations

Lessons for Manufacturing

What We Learned:

Parts organisation in bins is critical - group by assembly or function
Barcode scanning non-negotiable for complex BOMs
Kit verification before assembly saves significant rework time
Small fasteners require clear labeling and bin organisation
System handles both tiny screws and large structural components

Applicability:

Electronics assembly and kitting
Automotive parts kitting
Industrial equipment manufacturing
Any operation building complex products from many components
Spare parts kitting for service operations

This internal deployment proves Shelfbot works for manufacturing operations requiring precise kitting, complex BOMs, and zero-error assembly processes.