From robotics to artificial intelligence, here's how Amazon gets its products to Houstonians in record time. Photo by Natalie Harms/InnovationMap

How Amazon's Houston fulfillment center uses AI technology and robotics to move millions of products

Prime time

Last summer, Amazon opened the doors to its North Houston distribution center — one of the company's 50 centers worldwide that uses automation and robotics to fulfill online orders.

The Pinto Business Park facility has millions of products in inventory across four floors. Products that are 25 pounds or less (nothing heavier is stocked at this location) pass through 20 miles of conveyor belts, 1,500 employees, and hundreds of robots.

The center also has daily tours open to the public. We recently visited to see for ourselves the process a product goes through at this Houston plant. From stowing to shipping, here's how packages go from your shopping cart to your front porch.

Starting with stowing 

Natalie Harms/InnovationMap

A product's first step in an Amazon facility is stowing. There's no categorization of the products — it's not like there's one floor for one type of item or anything.

"It's completely randomly stowed," says Donna Beadle, PR specialist for Amazon. "She could be stowing cat food on this floor, and so could somebody on floor two."

An Amazon employee would scan an item and stow it into an empty bin of her choosing — sort of. To prevent confusion, a light projected indicates bins that are off limits to stow the item. The light identifies bins that have similar products. Keeping similar products apart helps prevents mistakes for the employee who later pulls those items once its ordered.

The system also sees where the employee is putting each item, rather than having to scan each item and the bin as well. This is a newer feature — the facility originally opened with hand-held scanners.

"Our next generation workstation is that they don't have to hold that scanner — they have hands free," says Brenda Alford, regional communications manager at Amazon.

Robots on the move

Once the bins are fully stocked, the robot — which is the orange device on the bottom of the yellow bins — moves about the facility by scanning QR codes on the floor.

Should a product fall out, an employee wearing a special vest can enter to retrieve it. That vest will send off a signal to the robots, which will then decrease their speeds and come to a stop when the employee comes close.

"It's an extra measure of safety so that people can interact with the robots and feel safe," says Beadle.

Picking before packing

Natalie Harms/InnovationMap

Once an item is ordered, the bin with that item appears in the pick process at the center. The system tells the Amazon employee which item to grab and which bin to put it in. The bins will have products for multiple different orders — another employee later will separate it out later.

"Often we describe it as a symphony — our technology and our associates working together," Alford says, noting that sometimes the company might receive criticism about using robots over humans. "We can't do this without these humans.

Amazon employees receive their benefits from day one on the job, Beadle says, and they work four, 10-hour days a week.

"We feel like that way they have more time with their families — they get three days off versus two days off. And that gives them time to heal and rest up," she says.

Bin to bin and back again

Natalie Harms/InnovationMap

Once full, the Amazon associate will push the bin onto a series of conveyor belts. The whole facility has 20 miles of conveyor belts — much of which happens overhead.

The bins then zigzag toward the pack process, which is separated to different stations. There are single-product stations and multiple package stations. The system determines where the bin should go, and some stations pack products that are determined to need packing materials, while others do not.

Single-product packaging

Natalie Harms/InnovationMap

At the packing process, the Amazon employee is told which size box to assemble — he or she can grab a bigger box, but they can't select a smaller one. The tape dispenser doles out the correct size of tape for that box automatically.

Once packaged up, a sticker with a barcode is placed on the box. This code will later be used to print the label for shipping. At this point in the process, no personal information has been revealed to anyone. In fact, most packages leave the facility without any personal information being viewed by employees.

In an effort to reduce packing materials, some products are shipped in the container they came in. In that instance, the packer would just place the barcode sticker on the package before sending it on the conveyor belt.

"If we don't need another box for that product, we don't use one," Beadle says. "We work with companies to make that happen, so we don't have to use more boxes if we don't have to."

SLAM 


While the robotics aren't slamming labels on packages, the SLAM process (short for scan, label, apply and manifest) is the first step in the process that includes a customer's personal information. During this process, the barcode is scanned, the package is weighed, and the label is printed and affixed to the package using a puff of air.

A package might be automatically pulled from the line if something seems to be off in the package's weight.

"Say you bought toothpaste, and it says that toothpaste weighs 20 pounds, we know something's wrong," Beadle says. "Like maybe that it was a pack that didn't get separated."

If the package is kicked off, an Amazon associate, called a problem solver, will assess the situation and make it right before returning it to the conveyor belt.

Kicked into gear

Once labeled, all the packages are sent on their final conveyor belt ride. Using a scanning process, the packages are kicked by an automated foot that sends them into a line to be loaded into an Amazon truck.

If a package misses its chute the first time around, it makes the loop again. The system can tell if a package is caught in the loop for whatever reason, and a problem solver might be called to assess the situation.

Down the slide

Natalie Harms/InnovationMap

After being kicked off the belt, the package then slides down a spiral chute that, despite looking like a playground slide, is off limits to any humans wanting to keep their job.

"People ask if you can go down the slide, and we always say that on your last day of work," Beadle jokes.

On to the shipping process

Natalie Harms/InnovationMap

The packages leave the facility in Amazon trucks and head to one more pit stop before making it to the customer.

"They don't go directly to your house after this process," Beadle says. "They go to a sortation center."

This could mean a USPS or UPS stop, but it depends on where the customer lives.

Ad Placement 300x100
Ad Placement 300x600

CultureMap Emails are Awesome

Texas university's new flight academy opens at Houston Spaceport

cleared for takeoff

The vehicles may not have “student driver” stickers on them, but Texas Southern University has moved a dozen planes into its new training facility at the Houston Spaceport, opening the way for student flyers to use the facility.

TSU previously reached a deal with Houston Airports and the City of Houston in 2023 to house its prospective Flight Academy at Ellington Field. At the time, TSU had a small fleet of nine planes for student use, but a $5.5 million investment from the city greatly expanded the space available.

The Flight Academy includes a 20,000-square-foot hangar that serves as a TSU satellite campus. The school now has a fleet of 12 Cirrus SR20 aircraft that were acquired last year through state and alumni funding. An additional 4,500 square feet is used as classroom and office space. An 8,000-gallon fuel tank will support flight training operations.

TSU first launched its Aviation Science Management program in 1986 and added a professional pilot program in 2016. The school is now part of the United Airlines pipeline program and has also forged relationships with Delta and Southwest.

“I want to commend Texas Southern University and Houston Airports for their leadership and partnership in advancing aviation education right here in our city,” Houston City Councilwoman Dr. Carolyn Evans-Shabazz in a press release.

“It connects our students to high-paying, high-demand careers in aviation and aerospace. This is how we grow a city in the right way—by investing in workforce development, aligning education with industry and making sure our residents are prepared to lead in the industries of tomorrow. Houston is already a global leader in aerospace and projects like this strengthen that position even further, especially here at Ellington, where innovation and opportunity continue to take flight.”

The City of Houston signed an agreement to continue funding the academy for five years.

Amazon launches ultrafast, 30-minute delivery service across Houston

Amazon Now

More than 20 years after it redefined fast shipping, Amazon is preparing to raise the bar on consumer expectations again by offering to fulfill customers' most urgent product needs in Houston and other parts of the world in a half-hour or less for an extra fee.

The company, which revolutionized online shopping in 2005 with two-day deliveries for Prime members, is rapidly opening small order-processing hubs in dozens of U.S. and foreign cities to cater to shoppers who can't or don't want to wait for cough medicine to relieve flu symptoms or tomatoes for tonight's dinner salad.

The ultrafast service, called Amazon Now, first launched in India last June. Amazon says 30-minute deliveries now are also available in urban areas of the United States, Brazil, Mexico, Japan, the United Arab Emirates, the United Kingdom.

The mini-warehouses devoted to Amazon Now are about the size of a CVS drugstore. They stock about 3,500 products for expedited delivery, including beer, diapers, pet food, meat, nonprescription medications, playing cards and cellphone charging cables.

“We know that customers love speed and always have,” Beryl Tomay, Amazon’s head of transportation, told The Associated Press on Monday. “What we see customers doing, when we offer faster speeds, are they purchase more from Amazon. And Amazon becomes more top of mind for that or other types of items as well.”

In the U.S., the company first tested Amazon Now in Seattle, the home of its headquarters, and in Philadelphia. Most residents of the Dallas-Fort Worth area and Atlanta now have access as well. The service is also live in Dallas-Fort Worth, Denver, Minneapolis, Phoenix, Oklahoma City, Orlando, and dozens of other cities, Amazon said, with New York City and others expected by year-end.

The service charges for Amazon Now start at $3.99 for Prime members, who pay an annual fee of $139, and $13.99 for non-members. A $1.99 small basket fee applies to orders under $15, Amazon said.

The company's bet on a need for speed also comes as some consumers are rebelling against rushed deliveries as they weigh the potential impact on the environment and the workers tasked with preparing orders at a rapid rate.

Amazon’s approach
A relentless focus on speed helped Amazon build a logistics and e-commerce empire. After it made two days the new delivery time normal, Amazon moved into one-day and same-day deliveries for its Prime members. This spring, the company began making 90,000 products available in one hour or three hours at an extra cost.

The scaled down and sped up microhubs that are designed to handle 30-minute orders represent another step in Amazon's pursuit.

Only a handful of people prepare orders from aisles of shelves in the 5,000- to 10,000-square-foot facilities, unlike the sprawling fulfillment centers storing millions of items where Amazon employs a mix of human workers and robotics to pick and pack orders.

Amazon tailors the product inventory to each location and uses artificial intelligence and other technology to analyze what customers buy, as well as when and how often. The most popular U.S. purchases so far include soap, toothpaste, mouthwash, toilet plungers, bananas, limes and wireless earbuds, Amazon said.

The competition
Amazon’s attempt to up the instant gratification ante provides direct competition to on-demand food delivery platforms like Instacart, Uber Eats, DoorDash and Grubhub, which don't have the scale of the e-commerce titan, according to independent retail analyst Bruce Winder.

“What Amazon brings is their prowess in supply chain,” Winder said.

These smaller companies said they don't see Amazon as a threat, though, citing the hundreds of thousands of items they are able to deliver to users' doorsteps by partnering with various merchants and restaurants.

“DoorDash has a mission to empower grocers and retailers and augment their existing footprint, not to replace them,” DoorDash spokesperson Ali Musa said in an emailed statement. “We win only when they win, which is how we can offer over half a million grocery and retail items in under an hour across the country.”

Amazon also is in a race with Walmart to become the retailer that reliably gets orders to online shoppers in under an hour.

For an additional $10 on top of standard delivery charges, shoppers can place Walmart Express Delivery orders from among more than 100,000 products that are guaranteed to arrive in an hour. Many customers, however, are receiving the items under 30 minutes, Walmart CEO John Furner told analysts in February.

Domino's cautionary tale
Companies have promised deliveries in 30 minutes or less before, but the landscape also is littered with failed attempts to break the speed barrier.

The COVID-19 pandemic produced a flurry of companies that promised 10- to 15-minute grocery deliveries from microwarehouses in dense neighborhoods, according to Sucharita Kodali, an analyst at market research firm Forrester Research.

But soaring operating costs, low customer loyalty and the drying up of investor money ultimately caused most to fail before the pandemic was over, analysts said.

Domino’s in 1984 pushed a guarantee that customers would receive their pizzas for free if they weren't delivered in under a half-hour. The company amended the “30 minutes or it’s free” policy after two years, providing only a $3 discount for late deliveries.

The promotion helped Domino’s win market share, but it ended up tarnishing the company's reputation. It dropped the guarantee in December 1993 after a string of crashes and lawsuits involving drivers racing to meet the deadline.

Brad Jashinsky, a retail analyst at information technology research and consulting firm Gartner, said he thinks Amazon should take the pizza chain's experience as a cautionary tale.

“You get in trouble when you start overpromising something like that,” he said.

Amazon won't be making any time guarantees and instead plans to keep customers who chose the 30-minute delivery option updated on the progress of their orders, Tomay said.

“There's no rushing either in our building workers or the gig workers,” she said.

Taking it slow
Kodali thinks Amazon will need a lot of people placing orders around the same time from the same or adjacent apartment buildings for the 30-minute service to be cost-effective.

Consumers may appreciate rapid receipt of products like toilet paper and batteries, but retailers and logistics experts said they also see some online shoppers, especially members of Generation Z, choosing no-rush shipping for products they don't need in a hurry.

Amazon for several years has invited customers to skip one- or two-day delivery and to receive their orders on the same day in as few parcels as possible. Consolidating orders into fewer packages by electing to have them delivered at the same time cuts down on boxes, shipping envelopes and fuel use, analysts said.

“The millennials who came to age in an era that was on fast delivery came to expect it de facto, whereas ... Gen Z is more accepting of a slower speed than previous generations before them,” said Darby Meegan, a general manager at Flexport, a supply chain and logistics company that fulfills orders for thousands of online merchants.

Still, Amazon executives have cited positive early results for Amazon Now in India, where they said Prime members tripled their requests for 30-minute deliveries once they started using the service.

Amazon Now also is attracting more repeat American customers, Tomay said.

“It’s in early days and time will tell,” she said. “I think that it will be interesting to see how it evolves.”

Houston company partners on AI-powered medical support for space missions

AI in space

Houston-based Aexa Aerospace has partnered with SpacePort Australia (SPA) to build medical AI solutions for space crews.

Known as The Hamilton Project, the collaboration aims to complete the training and refinement of a “deductive medical AI model” designed to aid and treat astronauts and space travellers. With limited to no real-time access to doctors on Earth during space missions, the project's goal is to create an AI model that would serve as a medical resource.

“‘The Hamilton Project’ is a sophisticated AI model, integrating academic and clinical knowledge in a unique way,” Aexa founder and CEO Feranando De La Peña Llaca said in a news release. “It is paving the way for future autonomous attending.”

The project is named after NASA flight surgeon Dr. Douglas Hamilton, who participated in 50 missions.

SPA, an independent research organization, will bring its practical medical knowledge and clinical experience to The Hamilton Project, which builds on Australia’s rural and remote medical training programs. SPA founder Dr. Gabrielle Caswell brings 20 years of remote medicine experience that SPA believes will help address the issues that could be encountered in space.

“Rural general practitioners in Australia practice ‘pre-cradle to grave’ medicine, including areas considered sub-specialities in most western countries: OBYN, paediatrics, trauma management, anaesthetics, general surgery, mental health and geriatrics,” Caswell added in the release. “This broad clinical skill set encompasses all stages and phases of human life. And importantly practitioners are also trained in the management of severe trauma. "It is anticipated that doctors and medical staff will become embedded into missions, and all these skills will be required over time, to create successful space economic zones.”

Aexa Aerospace’s previous work includes developing holographic medical devices that have been trialled on the International Space Station. Read more here.