Warehouses across the United States are increasingly turning to automation to address persistent labor shortages and accelerate fulfillment speeds, a trend that is no longer limited to large corporations. From simple mobile workstations to sophisticated robotic systems, companies are finding solutions to optimize operations and make the most of their existing workforce.
“You have to glance at warehouse workers as athletes and arm them to be as effective as possible,” explains Kevin Ledversis, vice president of Newcastle Systems, a manufacturer of mobile workstations and carts for industrial environments. “And you’ve got to treat people well, as labor is a commodity that’s getting scarcer. Treat them better, give them better tools—we’ve got to start working together as an industry [on that].”
A key focus of this automation push is reducing the amount of time workers spend traveling within the warehouse. Experts say minimizing travel boosts efficiency and frees up employees for tasks requiring more skill and judgment.
Simple solutions, such as powered mobile carts and workstations, are gaining traction. These rolling units incorporate computer terminals and printers, allowing associates to complete tasks anywhere in the facility. Ledversis argues these carts offer efficiency gains comparable to more complex robotic systems. “What we’re good at [is making] companies a lot more efficient—similar to picking robots or AMRs,” he said. “Carts really keep people from [having to walk] back and forth to computers.”
The reduction in travel time also minimizes errors. Ledversis cited labeling as a common example. Workers often print labels for multiple orders at once to avoid repeated trips to a central printer, increasing the risk of mislabeling and costly shipping errors. Mobile workstations allow workers to print labels directly at the point of packaging, improving accuracy.
More advanced automation, such as automated lift trucks, is also being deployed. Kyle Smart, automation sales manager at Yale Lift Truck Technologies, explained that these driverless vehicles are best suited for repetitive, predictable routes, such as transporting finished goods to loading docks or moving waste materials. “Typically, [automated forklifts work best for] transport that’s going to be upwards of 100 feet,” Smart said. He added that companies can achieve up to a 32% labor savings by automating these tasks.
Smart emphasized that successful implementation requires careful planning and a willingness to adapt. “If you run multiple shifts, the chances are that introducing automated lift trucks—again, connecting them to an applicable task—is going to be a very viable and right solution for you,” he stated. “You also need site readiness and a willingness to make the changes that are necessary to have an automated forklift solution do what you expect it to do and is meant to do.” This includes maintaining a clean facility, a reliable Wi-Fi network, and a commitment to technology updates.
The shift towards automation also necessitates upskilling the workforce. Smart suggested that employees can be redeployed to higher-value tasks, such as quality control and value-added assembly, or trained to maintain and troubleshoot the automated equipment, becoming “automation champions.”
Packaging supplier Orbis Corporation notes that automation is also impacting their industry. Andrea Nottestad, senior product manager at Orbis, said that automation creates opportunities to work with suppliers on converting inbound supply into returnable packaging that can go directly into automated systems. She recommends that companies engage their packaging suppliers early in the automation process to ensure seamless integration.
Nottestad also highlighted the safety benefits of automation, particularly in tasks involving repetitive motion or heavy lifting. “Automation is useful to minimize safety risks to our employees where repetitive motion or higher-weight loads can create risk,” she said. “An example is heavy parts, such as pallets and bulk bins, where utilizing automation allows us to mitigate risks with our employees.”