Why Pick to Tote Is Not Just a Workflow, but an Engineering System
For such a process to work, you need not just a WES, but a WES capable of managing the dynamic flow of robots and humans in real time.
Pick to Tote requires:- Precise synchronization across all system levels — from WMS to AMR controllers.
- Multi-level route planning — robots must move without conflicts, delays, or congestion in narrow areas.
- Predictive task allocation — the system must anticipate where and when a robot will be needed so the picker never waits.
- Flexible task prioritization logic — balancing speed, safety, and workforce utilization.
- Deep integration with equipment — robots, scanners, conveyors, scales — and adaptation to the specifics of each warehouse.
This is not an off-the-shelf solution. You cannot simply “connect a robot to the system.” Every integration requires configuring routing algorithms, safety zones, and data exchange interfaces.
Why Not All WES Companies Can Do This
Many warehouse management systems handle the orchestration of people and conveyors quite well.
But when mobile robots are introduced, especially in Pick to Tote scenarios, a whole set of engineering challenges arises that standard WES cannot handle.
Key Reasons:- WES architecture is not designed for dynamic objects. The system must respond instantly to changes in the environment: if one robot is delayed, another must be able to reroute immediately.
- Lack of an internal planning and flow simulation module. Without this, it is impossible to predict how dozens of robots will behave under real operational load.
- Insufficient integration with robotic platforms. Proper operation requires native connectors and APIs, rather than third-party add-ons.
- Limited expertise in engineering modeling. Pick-to-Tote is not just about IT; it requires a deep understanding of warehouse physics, including flow logistics, safety, and workplace ergonomics.
Outcome: Many companies can offer “simplified” scenarios with partial automation, but few are capable of implementing a true Pick-to-Tote system, where humans and robots operate seamlessly as a unified system.
How Displine Solves This Challenge
The Displine team is building a next-generation WES designed for seamless interaction with AMRs, conveyors, and humans within a unified system.
Our engineering solutions include:- Intelligent routing algorithms – the system dynamically assigns tasks to robots in real time, preventing collisions and downtime.
- Assembly station load planner – ensures that human operators are consistently supported by robots without creating queues.
- Accurate integration with WMS and equipment – a single database with continuous event exchange for smooth operation.
- Modeling and simulation tools – enable testing of scenarios before deployment in a live warehouse environment.