Warehouse automation is beginning to reshape logistics and supply chain operations by bringing significant benefits, including speed, efficiency, and reduced labor dependency. These capabilities will only increase with the proliferation of robotics and artificial intelligence in these facilities. However, many organizations still face serious hurdles when acquiring, integrating, operating, and maintaining automated systems.
To understand the current state of the warehouse, WTWH Media’s Automated Warehouse recently surveyed readers to understand what technologies are being used, the impact of those investments, and the areas of focus in the future.
Some of the key findings include:
- Capital investment poses challenges amid economic constraints and uncertainty.
- Operators see the need for new robotic systems with advanced vision systems and Internet of Things (IoT) integration.
- Respondents said they expect AI to affect productivity in the automated warehouse.
The report highlights some of these key findings.
Create an automated foundation
The primary job functions of the 96 survey respondents included manufacturing engineers, design engineers, system integrators, operations, and general management. The majority of them (57%) said they are currently evaluating or adopting new automated systems for the warehouse.
When asked what automation they use or are considering using, it’s no surprise that conveyors are the most common equipment within warehouses, fulfillment centers, and distribution centers. Considered the backbone of the automated movement, conveyors provide reliable transport of goods through a facility, especially in high-volume operations.
Similarly, automated storage and retrieval systems (ASRS) are popular, especially in space-constrained environments where they can increase vertical storage efficiency and reduce human travel time.
Meanwhile, picking systems, automated guided vehicles (AGVs), packaging systems, and robotic palletizing/depalletizing systems are also used to speed order accuracy, ease transport tasks, and improve efficiency while reducing workplace injuries.
To date, a full 69% of survey respondents said that the integration of automated systems moderately or significantly improved efficiency in the facility. Performance and return on investment (ROI) are measured by labor cost savings (56%), accuracy (49%), downtime (48%), throughput (36%), and space utilization (31%).
Automation obstacles: Cost, integration, labor
Of course, automation comes with its fair share of challenges. The leading one, cited by 59% of respondents, is the substantial capital investment required to implement automation.
From robotics and conveyor systems to software platforms, the initial costs can be daunting — especially for small to midsize facilities. Even with long-term ROI potential, the upfront financial commitment often slows adoption.
Nearly half (48%) of respondents reported integration with existing systems as a major challenge. Many warehouses operate with a patchwork of older equipment and software, and aligning new automation technologies with legacy systems can require complex custom solutions and significant IT involvement.
In addition, about 31% noted capability limitations, reflecting frustration with the rigid or task-specific nature of some automated systems. In environments where product types, volumes, or workflows change frequently, flexibility is key — yet many current systems struggle to adapt without costly reconfigurations.
Technical issues (26%) and a lack of skilled personnel (26%) are often interconnected. As automation grows more sophisticated, so does the need for specialized talent to install, troubleshoot, and optimize these systems.
Finding qualified staffers, or upskilling existing workers, remains a critical concern, as does system downtime (25%), the cost of maintenance (24%), and workplace safety concerns (23%).
A smaller portion (8%) cited “other” challenges, which may include regulatory hurdles, vendor reliability, space constraints, or environmental considerations unique to their facilities.
Automated warehouses can be safer
Protecting people is always a top priority, so when introducing automation into the warehouse, there must always be a plan in place to keep workers safe. This requires a proactive, multi-faceted approach. As technology evolves, so too must the strategies used to protect the people working alongside these systems.
Survey respondents noted the use of safety protocols (61%), training (60%), safety barriers and zones (56%), regular maintenance and assessments (41%), safety PLCs and controllers (32%), and advanced sensors and AI (26%) as the top ways they safeguard employees.
In addition, warehouse environments should be designed for ergonomics and to ensure that operators can access emergency stops (e-stops), manual overrides, and maintenance panels without strain or delay.
The future of the automated warehouse
Most respondents (57%) said they are making more technology investments, which is a smart decision. That’s because the automated warehouse is poised to become even more transformative in the next five to 10 years, driven by emerging technologies and shifting operational priorities.
The top technologies survey takers cited that will shape the future warehouse include:
1. Increased use of AI and machine learning (65%)
Topping the list of future trends is the expanded role of AI and machine learning. These technologies could help warehouses move beyond simple automation to intelligent systems that continuously optimize operations, predict maintenance needs, and enhance decision-making in real time.
From demand forecasting to dynamic inventory management, AI was seen as a critical enabler of smarter warehousing.
2. More energy-efficient systems (45%)
Sustainability is taking center stage, with nearly half of respondents anticipating more energy-efficient systems. This includes everything from low-power robotics to energy-regenerative conveyors and smart lighting systems that reduce overall environmental impact and operating costs.
3. Higher adoption of mobile robots (44%)
Survey respondents said they expect wider adoption of AGVs and autonomous mobile robots (AMRs) as the technology matures and their ROI becomes more evident. These mobile platforms are suitable for automating repetitive transport tasks and can be reprogrammed as warehouse layouts evolve, making them a versatile option for growing operations.
4. Enhanced safety features (44%)
Safety will continue to be a major focus, with improvements in sensors, machine vision, and predictive analytics driving enhanced safety features. Warehouse operators predicted more intuitive human-machine interaction, reducing the risk of accidents while improving overall worker confidence in the automated warehouse.
5. Greater integration with IoT devices (41%)
IoT will play a larger role in the connected warehouse, said operators. Smart sensors and real-time data streams could allow for seamless monitoring of equipment health, inventory levels, environmental conditions, and even worker productivity. This deep integration will support predictive analytics and tighter control over complex operations.
6. Emerging technologies (5%) and other innovations (3%)
Some respondents highlighted emerging technologies — such as autonomous drones, computer vision, and advanced materials handling systems — as the next frontier. Though not yet mainstream, these innovations could unlock new levels of efficiency, especially in large-scale or high-speed fulfillment environments.
Automated warehouses to get smarter
The next decade promises a wave of innovation that will redefine supply chain robotics. From AI-driven business intelligence to environmentally conscious systems and hardware advances, the automated warehouse of the future will be safer, more sustainable, more responsive than ever before.
For businesses that are ready to invest in these innovations, the reward will be not just operational efficiency, but also a competitive edge in an increasingly fast-paced and customer-centric market. As technology advances, the warehouse is no longer just a storage facility; it’s becoming a hub of intelligence, agility, and strategic value.
Editor’s note: ChatGPT assisted in shaping portions of this report. Learn more in the Logistics and Warehousing Track at the Robotics Summit & Expo in Boston.
