The COO’s Guide to Physical AI

From humanoids to VLA robot arms, here’s what you need to know to get ahead of AI’s next breakthrough.

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Summary

  • Physical AI is an AI model embodied in a machine, capable of reasoning, navigating, and acting in the physical world. Think humanoids, robot arms, AMRs, autonomous trucks.
  • The majority of executives believe physical AI will be a key driver of competitiveness. Deployments are scaling rapidly across supply chains at Amazon, UPS, BMW, Hyundai and BP.
  • Now is the time to move to make the most of the opportunity: set up your operational context layer and start early real-world pilots.

AI isn’t stopping at agentic

“The ChatGPT moment for physical AI is here — when machines begin to understand, reason and act in the real world.” That was Jensen Huang, at an NVIDIA keynote in 2026.

AI’s technological progress isn’t stopping at ever-improving agents. The next big breakthrough is around the corner. Physical AI was cited as one of Gartner's top strategic technology trends for 2026, and soon after Huang’s pronouncement, DeepMind Chairman Demis Hassabis echoed added: “We are on the cusp of a kind of breakthrough moment in physical intelligence.”

Real deployments are happening at scale, in companies like Amazon, UPS, BMW, Hyundai, DHL and BP – but what’s physical AI, and how will it impact supply chains?

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Peter Budweiser

Senior Director Supply Chain, Celonis

“Many supply chain leaders, rightly preoccupied with agentic AI, don’t realize that physical AI is right around the corner.”

What is physical AI?

Physical AI refers to an AI model that is embodied within a machine or device (think robots, self-driving vehicles), and that through movement, interacts with the real world. Like other AI models, physical AI is able to reason and react to unexpected scenarios it hasn’t been trained on or programmed for.

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Why does it matter?

  • The sector is growing fast, with live deployments at Amazon, UPS, BMW, Hyundai and BP.
  • Physical AI robots can act independently and navigate and work within complex environments, with the potential to hugely improve efficiency, quality, and safety.
  • When physical AI robots are connected to the context layer running across a supply chain, they feed and receive information end-to-end, allowing for greater adaptability and resiliency.

64%

of executives say physical AI is a key driver of competitiveness (Capgemini)

80%

of front-line workers will be assisted by physical AI by 2030 (Gartner)

$370B

the potential worth of the general-purpose robotics market by 2040 (McKinsey)

The physical AI robots that will have the most impact on supply chains

Vision-Language-Action (VLA) Robot Arms

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Today: There is already proven implementation of specialist arms governed by AI across logistics use cases with loading, unloading, storing and picking applications.

Tomorrow: Huge potential lies in more generalist robot arms. The challenge is with perception, force control, motion planning, error recovery: these all need to work simultaneously.

Key use cases

  • Pickle Robot & UPS: 400 Pickle Robot VLA robot arms deployed through 2026-27 as part of a wider $9B automation push. Pickle Robot arms are built to autonomously unload non-palletized trucks in under two hours.
  • Amazon: has developed and deployed a suite of VLA robot arms, named Sparrow, Robin, Cardinal, and Vulcan. Vulcan, the latest, is a touch-sensitive robot arm that stows and picks in fulfillment centers. According to Amazon, it’s the first robot that can ‘feel’ what it grips.

Find out how Pickle Robot increased operational efficiency, improved system resilience, and reduced time-to-value using LeafLabs’ Robotic Systems Intelligence solution.

Autonomous Mobile Robots (AMRs)

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Today: ​​AMRs are technically capable and are already delivering ROI.

Tomorrow: Progress will come from implementing AMRs more broadly while integrating them with other types of physical AI within warehouses, such as VLA arms and humanoid robots.

Key use cases

  • Amazon: introduced its first physical AI AMR, named Proteus, in 2022. Now deployed in 24 of its fulfillment centers, Proteus can navigate in the same spaces as human workers, transporting loads of almost 400kg. Its next evolution, currently being piloted, will allow Amazon workers to speak to it conversationally.
  • Locus & DHL: AMRs reached a landmark one billion picks for DHL in March 2026. This is the industry’s largest AMR partnership, with thousands of Locus Origin robots deployed globally across 40+ sites. DHL reports 30–180% gains in units picked per hour.

To get the full analysis on each physical AI device, download our free ebook, Physical AI Explained in 7 Robots.

Autonomous yard trucks

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Today: Autonomous yard trucks are already highly capable, performing complicated maneuvers such as precision-backing into dock doors.

Tomorrow: The next level of adoption will entail a redesign of yard facilities around autonomous operations (rather than around human requirements) allowing for more space-efficient storage and optimized movement within the yard.

Key use cases

  • Outrider: the key player in autonomous yard trucks, with an ecosystem of autonomous yard tractors, robotic trailer coupling distribution hubs, and site management software connecting to warehouse management systems. In 2021, it described customer Georgia Pacific as “the first company to perform autonomous yard operations in a production environment.” Outrider says it is currently working with 11 large priority customers that represent more than 20% of the yard trucks in operation today.

Humanoids

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Today: Humanoids are the most hyped, but face the widest gap to potential of all the physical AI robots featured here. With the exception of Digit in logistics (below), use cases are either pilots or small-scale first deployments.

Tomorrow: Experts diverge widely on how large the market for humanoid robots might be – Goldman Sachs expects approximately 250,000 humanoids to ship per year in 2030; while Bank of America forecasts nearly five times as many (1.2 million).

Key use cases

  • Digit (Agility Robotics) & GXO Logistics: GXO Logistics has hired Digit robots on a robot-as-a-service (RaaS) contract to move tote boxes in their logistics centers. The robots have moved 100,000 totes in over a year of continuous operation. Agility names this the first RaaS deployment of humanoid robots. Meanwhile, Toyota deployed seven Digit robots in its Woodstock manufacturing plant in Canada; and Mercado Libre has signed a contract for Digit robots.
  • BMW & Figure 03 (Figure) & Aeon (Hexagon): In a much publicized pilot program, Figure 02 robots handled over 90,000 parts across 1,250 hours at BMW’s Spartanburg auto production line, supporting the build of over 30,000 vehicles. A use case demonstration is currently ongoing with Figure 03 humanoids working on a parts sequencing task at Spartanburg. BMW has also begun another pilot of the AEON robot in their Leipzig plant.

The supply chain of physical AI: China and humanoid robots

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McKinsey predicts that the general-purpose robotics market could be worth approximately $370 billion by 2040, with around 50% of that value coming from China. In 2025, China named embodied AI a strategic ‘industry of the future’.

Currently, the country has a near-monopoly on humanoid manufacturing (90% of global production by volume, according to Morgan Stanley). China has been able to leverage its expertise from the supply chain and manufacturing of EVs, which require the same type of rare earths permanent magnets in motors as humanoid robots.

How to get your supply chain ready today

1. Set up your context layer now
  • You need a context layer to make agentic AI work across your supply chain. You’ll need it to leverage physical AI too. A context layer codifies your operational reality (what happened and why, what's happening now, and what’s likely to happen next), and connects it to your strategy (i.e. your goals, your KPIs, etc).
  • What you’re looking for is a complete throughline from top-level board room numbers to the individual actions that happen every hour of every work day, whether those actions are performed by humans, AI agents, or physical AI robots.
2. Treat operational data as a strategic asset
  • In order to improve, physical AI foundation models need huge amounts of training data. While LLMs were trained on the mass of language data available on the internet, physical AI has no comparable library of information. This is being addressed in two ways:
    • Live robots: training data is collected through already existing operating robot fleets and then fed back to train new, better models. This is how Amazon has been evolving its AMRs. Any new adopters of robot fleets will have to build up their own repository of data in order to improve performance over time.
    • Synthetic data: training data is now itself being generated by AI. NVIDIA’s Cosmos world foundation model does just that, by creating data/video that follows real-world physics.
  • The gap is closing fast. Gartner says that by 2029, AI agents are projected to generate 10 times more data from physical environments than from all digital AI applications combined.
3. Consider first pilots
  • Combine the importance of training data with physical AI poised to become a key driver of competitiveness, and you see the importance of not being left behind.
  • The earlier you start, even on a small scale, the more experience your robots will have of working in your supply chain environment, in order to learn and improve their performance. This takes time. If you start late, the costs of catching up will compound.

Jami Friedman

Executive Vice President, LeafLabs

"The more intelligent our machines become, the more they act like part of the workforce, and the more they need to be visible to the business. Physical AI won’t reach its potential until machine workflows are part of the same context layer that runs the rest of the enterprise."

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FAQ

What is physical AI?
Physical AI refers to artificial intelligence models embodied within machines or physical devices, such as robots and autonomous vehicles. Unlike traditional AI, physical AI interacts with the physical world, navigating spaces, manipulating objects, and reasoning through unexpected real-world scenarios.
How is physical AI different from agentic AI?
While agentic AI operates within digital systems (processing text, data, or workflows), physical AI combines digital intelligence with hardware actuation. It means that machines can perceive, move, and physically execute tasks in dynamic environments without requiring strict, pre-programmed instructions.
What are the key use cases for physical AI in supply chain management?
Primary supply chain applications include Vision-Language-Action (VLA) robot arms for unloading and sorting, autonomous mobile robots (AMRs) for warehouse material transport, autonomous yard trucks for trailer maneuvering, and humanoid robots for multi-purpose handling tasks.
What role does data play in deploying physical AI successfully?
Data is crucial for training physical AI foundation models. Because real-world physical interaction data is limited compared to large libraries of text on the internet, organizations rely on operating fleet telemetry and synthetically generated physics-based simulations (such as NVIDIA Cosmos) to continuously improve robot accuracy and decision-making.
How should companies prepare their operations for physical AI integration?
Organizations should start by establishing an operational context layer to connect strategy with real-time operational execution, capturing high-quality physical environment data, and launching targeted pilot projects early to build organizational readiness and fine-tune models within their specific operational environments.