Robots Take the Loading Dock (7/1/25)

Ellie Thornton

Hello and welcome back to Milestones Behind the Freight Curtain! I’m Ellie Thornton, and as always, I’m joined by the one and only Professor Steve DeNunzio. I can't believe it's already Episode 4! Steve, are you ready to talk robots on the loading dock?

Steve DeNunzio

Oh, you know it, Ellie. I mean, this is the stuff I live for. And honestly, after last week’s deep dive into the CSCMP Annual State of Logistics report and the scale of logistics costs, I’m kinda glad we’re getting into something a bit more, uh, sci-fi today. So, robots—let’s do it.

Ellie Thornton

Yeah, it’s wild, isn’t it? I mean, just a few years ago, the idea of a robot unloading a truck sounded like something out of a Pixar film. But now, you’ve got Boston Dynamics’ Stretch and Ambi Robotics’ AmbiStack actually out there, doing the work. DHL’s got seven of these Stretch robots in three states, and they’ve even named one “Johnny 5” right there in Columbus. Your backyard! I love that!!!

Steve DeNunzio

Yeah, and Johnny 5 is no slouch. My friend was at that Columbus DHL warehouse a couple of months ago—total logistics nerd field trip, by the way—and he watched Johnny 5 unload about 580 cases an hour. That’s, like, almost double what even the best human unloaders can do. It’s honestly a little humbling to see a robot outpace a seasoned dockhand.

Ellie Thornton

And it’s not just DHL, right? Walmart, FedEx, UPS—they’re all piloting or rolling out these robots. But Professor, why is truck loading and unloading such a tough nut to crack for automation? I mean, we’ve had robots in warehouses for ages, but this job seems to have been the last holdout.

Steve DeNunzio

Yeah, it’s a great question. I think, well, part of it is just the chaos factor. You’ve got these 53-foot trailers, packed to the gills with boxes of all shapes and sizes, sometimes floor-loaded, sometimes palletized, and the robot has to figure out how to grab each one without crushing it or, you know, dropping it on someone’s foot. The environment is cramped, the lighting’s bad, and the floor can be slick with snow melt in winter. It’s a real mess.

Ellie Thornton

And the robots have to make decisions on the fly, right? Like, “Is this box too heavy? Is it fragile? Where do I put it?” It’s not just brute force, it’s a puzzle every single time. I saw that AmbiStack actually trains its robots using a videogame simulation, so they can practice with weird-shaped parcels and heavy stuff before they ever touch a real box. That’s so cool!

Steve DeNunzio

Yeah, it’s like Tetris, but with real consequences. And, you know, as we talked about in our episode on AI in retail, the tech is only as good as the data and the training. These robots are learning to handle the unpredictable, which is what makes this such a breakthrough. But, I gotta say, even with all this progress, there are still some things robots just can’t do... yet.

Ellie Thornton

Right, and that brings us to the next bit: how these robots are actually learning to pack pallets. AmbiStack’s videogame training is fascinating—they simulate all sorts of scenarios, like stacking flat-screen TVs or those awkward bits of furniture that never seem to fit anywhere. The robot gets data on weight, fragility, center of gravity, and then decides where to put each item. It’s all about minimizing damage and maximizing space.

Steve DeNunzio

Yeah, and it’s not just AmbiStack. You’ve got Dexterity’s DexR, which FedEx is piloting. That one’s got two arms and can build cargo walls inside a trailer, simulating billions of arrangements in, like, half a second. Then there’s Pickle Robot’s Dill, which is more about unloading, and Ancra Systems’ Skateloader, which uses conveyor belts to load or unload standardized goods super fast. Each company’s got its own flavor of solving the problem.

Ellie Thornton

But here’s the thing, Steve—do you think these systems will ever fully replace the human eye? I mean, I’ve seen some of these robots struggle with, like, a leaky bag or a box that’s thinner than a pizza. There’s always that one odd-shaped parcel that just doesn’t fit the algorithm.

Steve DeNunzio

Yeah, I’m, uh, I’m skeptical. I mean, the robots are getting better, but there’s still a gap when it comes to the weird stuff. Humans have this intuition—like, you just know when a box is about to fall apart, or when you need to double-tape something. The robots, they’re learning, but they’re not quite there. AmbiStack can simulate heavy, irregular items, but if you throw in, say, a beanbag chair or a busted box, it still might call for help.

Ellie Thornton

Exactly! And sometimes, the best solution is a bit of creative thinking—like, “Let’s wedge this lamp between two cushions so it doesn’t break.” I don’t know if a robot’s ever going to have that kind of, I dunno, warehouse street smarts. But, to be fair, the tech is moving fast. I mean, we’re already seeing robots that can adapt in real time, and that’s something I wouldn’t have believed five years ago.

Steve DeNunzio

Yeah, and, you know, as the tech gets better, the line between what’s possible and what’s practical keeps shifting. But for now, I think there’s still a place for humans—especially when it comes to the exception cases. The robots can handle the bulk, and the people can handle the weird stuff. At least that’s what I think!

Ellie Thornton

And that’s a perfect segue into the human side of all this. Because, let’s be honest, the impact on workers is huge. On one hand, you’ve got fewer injuries—no more “pepper of bruises” from unloading in the summer heat, as one dockhand put it. But on the other, there’s real anxiety about job security. Some folks are worried these robots are just going to take over.

Steve DeNunzio

Yeah, and I get it. I mean, the Bureau of Labor Statistics says warehouse laborers have one of the highest injury rates—almost five injuries per hundred workers. So, reducing that is a big win. But, you know, as we saw with DHL, they’re retraining staff to be “robot coaches.” Nearly a hundred associates have learned to operate and monitor the Stretch robots. So, it’s not about cutting jobs—it’s about changing them.

Ellie Thornton

Totally. And I’ll be honest, my first warehouse job was brutal. I was nineteen, working nights, and I’d come home with sore knees and bruised shins every shift. If I’d had a robot partner back then, I might’ve actually enjoyed it! But I do wonder—are we creating better jobs, or just fewer ones? Like, is being a robot coach really more fulfilling than being on the dock?

Steve DeNunzio

That’s the million-dollar question, right? I think for some people, it’s a step up—less physical strain, more technical skills, maybe even better pay. But for others, especially if you love the hands-on work, it might feel like a loss. And, you know, unions are already starting to push for rules around robot work, so human crews still get hours on mixed shifts. It’s a balancing act.

Ellie Thornton

And it’s not just about jobs, it’s about dignity, too. No one wants to feel like they’re being replaced by a machine. But if we can use robots to take away the worst parts of the job—the injuries, the heat stroke, the endless turnover—maybe that’s a win for everyone. I guess time will tell.

Steve DeNunzio

Yeah, and, uh, as we’ve seen in past episodes, whether it’s AI in retail or the big swings in spot rates, the only constant in logistics is change. The key is making sure people aren’t left behind as the tech moves forward.

Ellie Thornton

Couldn’t have said it better myself. That’s all for this week’s episode of Milestones Behind the Freight Curtain. Thanks for joining us as we peeked behind the loading dock door—robots and all. Steve, always a pleasure.

Steve DeNunzio

Always great, Ellie. And thanks to everyone listening. We’ll be back next week with more supply chain stories and, I’m sure, a few more robots. Take care, everybody. And stay cool in this Midwest heat wave!

Ellie Thornton

Just 22 Celsius in London! See you next time!