Robots in inventory management: automation combats shelf gaps and inventory problems

For retail companies, inventory management can sometimes feel like fighting a losing battle: it always seems like something is missing somewhere, and the days when stores could be closed “for inventory” are long gone. The two biggest hurdles to successful inventory management are the high time and personnel costs involved. Fortunately, specialized robots have been available for several years now as tireless helpers that keep an eye on inventory while searching for shelf gaps.

Despite all the difficulties of inventory management, brick-and-mortar retailers must strive to always keep their product range as complete as possible. Otherwise, customers will migrate to the competition next door or online.

Robots that regularly patrol the store independently and scan the shelves for missing or misplaced goods offer new opportunities to check and replenish inventory. They can relieve staff, save time, and make inventory faster and more efficient. This gives employees the opportunity to focus on important tasks such as customer contact and advice.

The use of robots is not yet widespread, but they have been and are being tested by companies such as DM, SPAR, REWE, Decathlon and Adler, SpartanNash, HomeBase USA, and Kroger. The following overview shows how robotics can change inventory management.

These are the most common pain points in achieving continual product availability at the shelf:

• Goods are missing from the shelf despite being in stock in the warehouse
• Delayed or incorrect inventory recording
• High time and personnel costs for manual counting
• Misplaced products or incorrect labeling
• Insufficient transparency regarding out-of-stock situations
• Lack of planogram compliance

Automated shelf checks enable precise recording of product inventory directly on the sales floor. Robots use various technologies to perform shelf scanning routines, detect shelf gaps in real time, and record discrepancies in inventory, price tags, or product location. Unlike manual checks, they work systematically and without distraction, often outside of opening hours and tirelessly, provided they have sufficient battery capacity. The data collected in this way flows into dashboards or warehouse management systems. On this basis, replenishment processes can be initiated in a targeted manner and inventory data can be continuously updated.

Out-of-stock detection: Detects whether a product is currently sold out or unavailable, even though it is listed.

Shelf scanning: Automated recording of shelf status using cameras or sensors. Detection includes gaps, misplacements, and label errors.

Inventory: Periodic counting of stock, often required by law. The goal is to obtain a complete picture of warehouse and shelf stock on a specific date.

A digital twin of a store virtually replicates a real sales area – including shelf structure, product placements, and current availability. To do this, robots collect detailed data on product locations, shelf gaps, and inventory during each shelf scanning cycle. The information obtained is used to create a digital twin of the story: retailers thus receive a visual, up-to-date image of their store that can be used for inventory management.

On the one hand, the use of robots in inventory management promises more accurate data, faster processes, and less manual effort. On the other hand, investments in hardware and IT infrastructure are necessary.