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Inside an Amazon Warehouse

redletterdave writes "In each one of Amazon.com's 80 fulfillment centers around the globe, Amazon relies on barcodes and human hands rather than robots or automation to find and ship the proper items in a quick and efficient manner. Without robots, Amazon utilizes a system known as 'chaotic storage,' where products are essentially shelved at random but are tagged with barcodes to be scanned at every step of the ordering, selection and shipping process. The real advantage to chaotic storage is that it's significantly more flexible than conventional storage systems. If there are big changes in a product range, the company doesn't need to plan for more space, because the products or their sales volumes don't need to be known or planned in advance if they're simply being stored at random. Free space is also better utilized in a chaotic storage system, and it's also a major time saver to not organize products as they come in. This system is the true key to Amazon.com's success in online retail."

27 of 206 comments (clear)

  1. My desk isn't a mess! by Anonymous Coward · · Score: 5, Funny

    I utilize a chaotic storage system.

  2. Hmm... by Anonymous Coward · · Score: 5, Funny

    It sounds like someone needs to run a defrag on those warehouses.

    1. Re:Hmm... by gagol · · Score: 4, Funny

      Have you ever tried to get a teenager to defrag his room?

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      Tomorrow is another day...
  3. May be an interesting slide show... by wvmarle · · Score: 4, Insightful

    May be nice if that site works with the latest Firefox, too... been a while since I had an issue with a site just not working.

  4. ADHD girl by girlintraining · · Score: 5, Funny

    My room is a disaster. My bed isn't made, nobody can find anything in here but me, and I have a couple bras right now hanging on the lamp to dry because there's nowhere else to put them. According to this article, I should be a major, successful retail vendor. So if that's true, instead of expecting me to be a billionaire or the President, my mom keeps telling me that at this point, she'd be happy if I'd just breed?

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    #fuckbeta #iamslashdot #dicemustdie
    1. Re:ADHD girl by Daniel+Dvorkin · · Score: 5, Funny

      Barcodes! You need barcodes!

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      The correlation between ignorance of statistics and using "correlation is not causation" as an argument is close to 1.
    2. Re:ADHD girl by girlintraining · · Score: 4, Funny

      Barcodes! You need barcodes!

      To breed? Jeez... I knew I was missing something obvious.

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      #fuckbeta #iamslashdot #dicemustdie
    3. Re:ADHD girl by jamesh · · Score: 4, Funny

      my mom keeps telling me that at this point, she'd be happy if I'd just breed?

      Just don't breed with a fellow geek or your kids are likely to turn out just like you, only more so. Just like us male geeks should be going for the prettiest, bimboest, bikini babes we can find, you should be going for a handsome jock who prefers grunts to words. Have fun with that ;)

      I married for beauty rather than for brains... unfortunately she turned out to be just as geeky as me and as a result my oldest daughter is almost too nerdy to function :)

    4. Re:ADHD girl by jones_supa · · Score: 4, Funny

      My room is a disaster. My bed isn't made, nobody can find anything in here but me, and I have a couple bras right now hanging on the lamp to dry because there's nowhere else to put them. According to this article, I should be a major, successful retail vendor.

      Correlation is not causation!

    5. Re:ADHD girl by flyingfsck · · Score: 5, Funny

      You mean Bracodes...

      --
      Excuse me, but please get off my Pennisetum Clandestinum, eh!
    6. Re:ADHD girl by sa1lnr · · Score: 4, Funny

      Oh man, little do you know.

      There's a veritable minefield of codes to navigate when it comes to women. :)

  5. Walmart do the same by Anonymous Coward · · Score: 4, Insightful

    If you've ever worked at Wallmart or I guess any of the other major supermarkets, they do the same thing. Store stuff whereever and track where it is. So it might be organized on the computer, but in the storerooms its real-world location bears no relation to it's computerized structure.

    Again for the same reason, seasonality and holidays etc. mean the sales are not constants and stocks of different items vary, and with small space at the supermarket for storage, it doesn't make sense to dedicate empty space to storing *potential* stuff.

    But hey, perhaps Bezo's plans to patent it, like one click ordering. So he's pretending it's a new thing.

  6. Re:Humans? by Ozeroc · · Score: 5, Informative

    Yeah, I've read that fulfulment warehouses are a terrible place to work: http://www.alternet.org/story/154344/what_happened_when_i_got_a_job_at_a_soul-crushing%2C_abusive_warehouse

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  7. Humans vs. Robots by gentryx · · Score: 4, Interesting

    Chaotic storage works because the barcode of each shelved item is scanned together with the barcode of its shelve, so that the computer can later on tell the humans where to find the stuff for a certain order.

    Apparently there is no reason why this wouldn't work with robots. Apparently robots are still to expensive or not smart (in terms of physical skills) enough.I wonder when we'll see Amazon experimenting with robots.

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    Computer simulation made easy -- LibGeoDecomp
    1. Re:Humans vs. Robots by wvmarle · · Score: 5, Insightful

      It's likely mostly the physical skill of opening a wrapper and taking a book out of it. Or worse, some odd shaped item. That's stuck in the tight wrapper.

      The first (and only photo visible to me) on that that site showed a bunch of shipping pallets aligned haphazardly with cartons stacked on top of them. Assuming one item per pallet, you go find the pallet (easy), then find which carton is currently open already (harder), then manouvre your arms and hands to take an item out of the carton (that's the tough one - especially the getting your fingers around it part), and place it in your shopping trolley or whatever they use there (easy again).

      Finding and scanning bar codes may also be tricky, as they're likely not on fixed locations.

      Current robots work where a blind man could work. They are as good as blind, after all. And need to know exactly where to find a product, and how to take one and only one. That's not easy with all those odd shaped, and constantly changing products.

  8. Re:Humans? by TheLink · · Score: 5, Informative

    Not true. They bought Kiva. It probably takes a while before they work out the changes needed and roll that out.

    As for humans getting rest, in many countries if you end up without a job and are not in the "ruling caste" the rest of the people don't seem to think you deserve to get any $$$$ for "resting" aka "doing nothing productive".

    Careful for what you ask for, you may get it.

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  9. Not all roses... by Anonymous Coward · · Score: 5, Interesting

    I work in a fulfilment centre myself, and i can say that while the storage is very efficient, as mentioned, the algorithms that rout pickers to collect the various items leave a lot to be desired. Its all well and good having ingenious storage systems, but if you have to spend 2 minutes walking to a particular shelf location to collect item X passing 8 different bins containing item X along the way, it wastes huge amounts of time and effort. For example, our fulfilment centre is LOSING $250000 due simply to pick-routing inefficiencies...

    1. Re:Not all roses... by Anonymous Coward · · Score: 5, Insightful

      The reason you have to go to a particular bin is that the company likely runs a FIFO inventory system, so they want you to pick the oldest items first. There are various good reasons to do this (we do it too in normal manufacturing inventory).

    2. Re:Not all roses... by hibiki_r · · Score: 4, Interesting

      The traveling salesman only becomes hell when the number of stops is very high, and it is relatively expensive to know the cheapest route before point A and point B. The thing is, neither of those is true in a warehouse.

      I don't know how long a typical route is for an Amazon picker, but when I was writing warehouse software, pickers were only getting about a dozen items per trip: typically far larger than a book. With so few items, and a warehouse that is not really a random graph, we were able to get extremely good solutions for picking. As an approximation, just try to a mock traveling salesman problem in a square grid, where you can only travel on both axis.

    3. Re:Not all roses... by Hulfs · · Score: 4, Insightful

      As someone who spent some time several years ago developing a picking algorithm for plumbing / electrical warehouses, there's generally much more to it than just a simple scanning / shortest path equation. You'll generally want to make sure you're going through your older stock first so you don't end up with old, unsellable stock, sometimes you want to actually clear out bins that have only a few items in them to make room for more stock, and many more things. So, just because you may walk by a few bins that have your item in it already doesn't mean the algorithm is dumb (though it very well may mean that), it may mean that those who set up the system assigned higher value to other picking / service priorities than just pick speed.

  10. Re:Humans? by uncqual · · Score: 4, Interesting

    As others have noted, Amazon purchased Zappos which utilizes Kiva in their warehouses. I expect Amazon to adapt Zappos models more than Amazon to migrate Zappos to their model. Every time a robot/computer replaces a human (been going on for 40 years), the fractional replacement human is a high skilled person than the multiple people they replaced. Think stocking -- the programmer costs a lot more and requires a lot more education than the human picker -- but the programmer's work can be deployed without limitations to service 6 billion people (and more later).

    The first world societies have to understand real soon that they need to figure out what to do with the jobless masses with IQs under 110 in fifty years. The answer can't be "pay them to breed more crack babies", the answer has to be "each generation values breeding less and eduction more" - or expect their economy to sink under the economic sea like most of the PIGS probably will.

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    Why is there an "insightful" mod and why isn't it "-1"? If I wanted insight, I wouldn't be reading /.
  11. Breaking News From 2107 by smittyoneeach · · Score: 4, Funny

    Amazon announces that, after a century of tweaking about, they have arrived at a self-replicating fulfillment warehouse system.
    Everything is on 23 pairs of rows. The tips of the 23 rows of two warehouses break off intermittently, and circulate freely on the roadways disguised as traffic.
    If any two sets of 23 show up in a fulfillment center parking lot and collide, a new fulfillment center is 'conceived', and 'gestates' for a few seasons before making a the shortest possible journey to a new location, where it starts doin' its thang'. A shocking amount of the row storage is metadata, such that a warehouse query fails outright or returns a product at roughly ludicrous speed. "Yeah, it's kind of a b-tree on Brawndo," said Dr. Joey "TT" Torvalds-Tridgell, the 800lb Brain of Amazon.
    In other news, Walmart President Sanger is seeking to legalize the abortion of this burgeoning threat, saying that wanton murder, too, is a form of capitalism.

    --
    Get thee glass eyes, and, like a scurvy politician, seem to see things thou dost not.--King Lear
  12. True key to success by agentgonzo · · Score: 4, Insightful

    "This system is the true key to Amazon.com's success in online retail". That, and not paying any tax.

  13. Barcode bugger-ups: big problem. by Bieeanda · · Score: 4, Interesting
    A few years back, someone ordered a book for me from Amazon. The package arrived as normal, but it was a completely different book inside, and one that I already had. So the sender got in touch with Amazon, the order was double-checked, and after some back and forth they sent a new package out.

    The second package had the same book in it.

    So did the third.

    It turns out that for some reason, possibly because they were part of the same product line, these two books were assigned the same Amazon-internal barcode. Because of this I never got the book that was ordered, but instead ended with two copies of the book that was mistakenly sent, and a credit for the cost of the original order.

    What might have been an easily remedied issue, had storage followed a logical pattern and the fulfillment person given enough autonomy to detect and solve the problem, ended up taking months to get to the bottom of.

  14. It works great by sjbe · · Score: 5, Interesting

    Since there's no organizational scheme, I assume that the human workers have to be told turn by turn where to go?

    There is an organizational scheme, it's just not by by product and workers will be told where to go regardless of what storage system the company uses. I implemented a version of this about 10 years ago in our warehouse for an auction company I owned. Basically you build a warehouse with identifiers on the shelving system. Then you assign a random and (this is the important bit) uniformly distributed code to each box/pallet/SKU that you store. You can't tell where a product is by the product, you have to look up the location in the computer but after that it's easy to find. This system works really well when you have a wide array of rapidly changing merchandise that you can't predict arrival times or quantities for. Amazon would be a great fit for a warehousing system like this.

    This kind of storage scheme means that the human workers are simply meat waldos serving the computer software that runs the place.

    That's true for pretty much all warehouses regardless of organizational scheme. Once you get to a warehouse of any size you have to have a computer to direct where to find merchandise to pick to an order. Even if the worker knows where to get it they still will need direction from the computer on quantities to pick.

  15. Link to photos by pancake_lover · · Score: 4, Informative

    The article slideshow isn[t working for me. Some photos from an Amazon warehouse were posted on reddit the other day. Here are those photos: http://imgur.com/a/q1WIO.

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    Homer no function beer well without.
  16. Re:Humans? by SirGarlon · · Score: 4, Insightful

    The first world societies have to understand real soon that they need to figure out what to do with the jobless masses with IQs under 110 in fifty years.

    Well, the problem of "masses" is taking care of itself. No need for government policy there; market forces are driving population growth down.

    As to the "IQ under 110," there are lots of productive and necessary jobs that can't easily be automated. It's going to be a long time before a robot can cook a gourmet meal or repair a leaky faucet or give me a good haircut.

    One doesn't need to be educated or even terribly smart to be a productive member of society. One just needs a work ethic.

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    [Sir Garlon] is the marvellest knight that is now living, for he destroyeth many good knights, for he goeth invisible.