Things to Consider Before You Automate
When a solution provider evaluates an opportunity for automation, the process begins long before any technology is selected. The first step is understanding the client’s current operation: the processes in place, how people and products move through the facility, and where inefficiencies may be hiding. From there, they work collaboratively with the client to define ideal processes and long-term goals. The critical question becomes whether the existing infrastructure can be aligned with those goals—or whether automation is the next logical step. For the purposes of this blog, “automation” and “robotics” refer broadly to the full range of robotic and automated material-handling technologies available today.
Start with Process Improvements
In many brownfield facilities—those already in operation—clients may prefer to pursue incremental improvements before committing to automation. Solution providers often begin by asking foundational questions about current workflows:
- What type of environment are associates picking from—bins, chutes, shelving, or conveyor lines?
- How far do they travel from pick to place, and is the travel pattern efficient?
- What are workers placing items on or into, and is that motion optimized?
- Are machines or storage locations slotted intelligently?
- Can product families or high-velocity SKUs be grouped more strategically?
In many cases, improving slotting, reorganizing pick paths, and tightening travel distances can yield meaningful gains. It’s not uncommon to uncover a 10–20% improvement in throughput simply by redesigning processes rather than introducing technology.
However, if a solution provider determines that process adjustments cannot meet the client’s goals—or if the potential return is too limited—robotics becomes a strong contender. Today’s automated options are broad: autonomous mobile robots (AMRs), follow-bot systems that handle travel for workers, robotic picking arms, autonomous forklifts, and more. Many of these solutions can deliver 30–50% performance improvements, making them attractive for operations facing sustained labor shortages or volume growth.
Understanding Spatial Requirements
Once a client decides to move forward with automation, physical space becomes the next major consideration. Robots do not operate in a vacuum—they require thoughtful integration into the facility.
Solution providers examine factors such as:
- Whether picking takes place at floor level, in shelving, or on a mezzanine structure.
- The amount of space needed for the automation to enter, exit, queue, and operate safely.
- How existing racking or shelving might need to be adjusted, replaced, or reconfigured.
- Whether smaller or larger pick paths should be created to optimize robot movement.
Beyond the picking engine itself, there are many external elements to evaluate: conveyors, palletizers, packing stations, racking systems, floor conditions, and even sprinkler systems. Some robotic solutions require specific floor flatness standards or infrastructure upgrades. It’s essential to address these changes before the robots arrive on site.
After installation, organizations must also invest in training—for associates, supervisors, maintenance technicians, and IT or controls teams. New software, physical behaviors, and safety protocols all require thoughtful adoption.
Labor and ROI Considerations
A space analysis is only one piece of the puzzle. Solution providers also conduct a detailed labor analysis to understand how automation might shift roles or reduce repetitive tasks. With robotic solutions available at a range of price points, this analysis helps clients begin to model what return on investment might look like, both in the short and long term.
Business Readiness Matters
Finally, organizations must reflect on the human and cultural side of automation. What is the internal appetite for change? Companies with long-tenured employees—some with 10, 15, or 20 years of experience—may encounter natural hesitancy toward new technology. Including frontline associates early as stakeholders helps build engagement, reduces resistance, and ensures a smoother transition.
And of course, leadership alignment around ROI expectations is critical. Some organizations prioritize rapid payback; others are comfortable with longer-term investments that better support strategic goals.
Information provided by Greg Meyne, enVista.
Learn more about The Robotics Group (TRG): mhi.org/trg
For further articles from the The Robotics Group (TRG):
Scaling Warehouse Automation: Insights from the Field
From Vision to Reality: Implementing Robotics in the Modern Supply Chain
Maximizing ROI and Mitigating Risks with Robotics
How Robots Positively Impact the Labor Shortage
