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Walmart's warehouse robots stumble on cardboard boxes and frozen turkeys in costly automation push

Published
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12

Why it matters

Walmart's decade-long, multibillion-dollar effort to replace warehouse workers with robots is running into technical and financial problems. Robots struggle with "breakpack," the step of removing items from cases for individual shipment, and oversized goods like dog food still require manual handling. Walmart has switched to shorter boxes that must be taped shut, which adds cost, and its small wheeled transport robots break down often. At a California grocery warehouse, robotic arms repeatedly fumbled large frozen turkeys, and shipments had to be rerouted. Walmart's head of U.S. supply chain operations, Rob Montgomery, said the company has reached "peak complexity" as it moves most of its roughly 200 U.S. supply chain buildings toward greater automation. The main partner is Symbotic, a Massachusetts robotics firm that handles nonperishable goods. Walmart owns a 12.6% stake in Symbotic, previously bought Alert Innovation before selling it to Symbotic, and, according to SEC filings cited by a single analyst, accounts for about 85% of Symbotic's sales. The two companies have worked together since 2015, and their extended agreement will bring robotics to 25 regional distribution centers. The news coincided with the opening of a 900,000-square-foot automated fulfillment center in Stockton, California, Walmart's fifth next-generation site.

Several key points are not settled. Walmart has spent nearly $1 billion since 2016 on automating in-store online order fulfillment, and it still has no workable model for that system. Symbotic reports that fewer than 5% of its product-moving robots were under repair recently, down from under 10% a year ago, but the company has not published independent verification. The 85% revenue concentration rests on one analyst's reading of SEC filings. A separate report puts peak monthly electricity costs at automated grocery facilities near $800,000, compared with about $250,000 under manual operations, but the report's methodology is not public. Executives told the Wall Street Journal that automation will eventually reduce warehouse headcount, but they have not announced layoffs. Symbotic expects its upgraded SymMicro ecommerce system to be running in about six months, and it reportedly does not expect a workable in-store pickup model until 2028.

For attorneys, the concentration of this deal is the main issue. A single vendor serving as both a major shareholder and the dominant customer of its automation partner creates related-party, disclosure, and dependency questions that counsel should review in any contract or financing involving either company. Watch for SEC filings that confirm or revise Symbotic's customer concentration, since they will show how much Walmart's automation timeline affects the vendor's finances. Labor counsel should track how Walmart handles workforce reductions as high turnover allows attrition instead of layoffs, since any change in that approach could raise notice or bargaining issues. Companies with older facilities planning similar retrofits should note that the project's costs and delays are coming from building age and the need to keep operations running, which could affect the timing and terms of their own vendor agreements.

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