Is the last "human fortress" of the logistics industry about to fall? Robots officially take over truck loading and unloading work

The rapid advancement of robotics technology is tackling the last automation challenge in the logistics and warehousing industry—truck loading and unloading work. This technological breakthrough, regarded as the "Holy Grail" of warehousing logistics, is expected to fundamentally change the high-intensity labor model that retailers and courier companies have long relied on.

Logistics giants like DHL, UPS, and FedEx have begun to deploy unloading robots on a large scale. DHL has deployed seven Boston Dynamics Stretch robots in supply chain facilities across three states and signed an agreement in May to purchase an additional 1,000 units. One of the robots, named "Johnny 5," can unload approximately 580 packages per hour, nearly doubling the efficiency of manual labor.

This technological transformation will significantly reduce labor costs and the risk of workplace injuries for logistics companies. Truck loading and unloading work has long faced recruitment challenges, as workers need to handle packages weighing up to 70 pounds in harsh environments, leading to common injuries. Boston Dynamics estimates that the return on investment for its robots is about two years.

Advancements in sensors, algorithms, and AI technology enable robots to perform this complex task, akin to "3D Tetris," marking a new phase in warehouse automation.

Sensors, Algorithms, and AI: Robots Transform into "Stacking Experts"

For a long time, retailers and parcel carriers have faced a tricky problem: the heavy and monotonous nature of truck loading and unloading work leads to high employee turnover. Whether in the sweltering summer or the frigid winter, handling heavy boxes inside metal trucks is a significant challenge, and workplace injuries are commonplace. Therefore, automating this process has always been the "Holy Grail" of the warehousing logistics field.

During loading, packages need to be cleverly stacked to maximize space and must be sorted by weight—the heaviest items placed at the bottom to prevent tipping or damage. Unloading is equally challenging, as operators need to frequently enter and exit the truck, handling packages of various sizes and weights. Today, most internal warehouse tasks are highly automated, yet truck loading and unloading still primarily rely on manual labor. Workers engaged in these tasks report that they need to stand for long periods and handle boxes weighing up to 70 pounds (approximately 31.7 kilograms).

However, with the continuous advancement of robotics technology, this situation is being completely transformed.

Recently, engineers at Ambi Robotics designed a video game to train their robotic stacking system, AmbiStack. According to Jeff Mahler, co-founder and CTO of Ambi Robotics, this game simulates various challenging scenarios, including heavy packages and oddly shaped boxes.

Another company, Boston Dynamics, has designed a robot named "Stretch," which features flexible robotic arms that can easily reach the top corners of a truck. This robot is equipped with a vacuum gripper with suction cups, capable of lifting boxes weighing up to 50 pounds (approximately 22.7 kilograms).

Efficiency Boost: Automation Practices of DHL and UPS

DHL has currently deployed 7 Stretch robots across supply chain facilities in three states and has trained nearly 100 employees to operate these devices. In Columbus, Ohio, a Stretch robot nicknamed "Johnny 5" by DHL employees can unload about 580 boxes per hour, with efficiency nearly double that of human unloaders.

In May, DHL signed an agreement with Boston Dynamics to purchase an additional 1,000 robots. United Parcel Service (UPS) is also increasing the automation level of its facilities, including the truck loading and unloading processes. UPS executives stated in April that this move would help the company reduce costs. FedEx has been collaborating with the robotics company Dexterity since 2023 to test and improve truck loading processes in one of its facilities. Walmart has also introduced robots capable of unloading trucks.

Sally Miller, DHL's Global Chief Information Officer, stated that DHL is looking for a robot that can handle different products flexibly, move in and out of trailers, and does not require significant capital investment. She noted:

"These jobs are hard to fill, especially the unloading of trailers during the warmer months."

Although the Stretch robots currently have some difficulty picking up thin packages and cannot yet unload bagged items, the company estimates that the return on investment for these robots is about two years. The company declined to disclose the specific price of each robot