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Robotic warehouse systems are becoming increasingly necessary in modern industrial operations, particularly as many facilities deal with larger order volumes and shorter delivery timeframes. However, making this technology part of the workflow often comes with challenges. Here are some of the most common, including how to solve them.
Alleviating Workers’ Concerns About Robotic Warehouse Systems
When workers hear their employers will bring robots into the warehouse soon, they often worry the machines will take their jobs. However, the typical outcome is companies use robots to do the repetitive or dangerous roles humans dislike. Then, the people who used to do those responsibilities can get transferred into rewarding, higher-value work.
Even so, many workers still have fears about their workplaces using robots. A 2022 study examined this matter in depth to get warehouse workers’ feelings about automation. The overall sentiment was 60% positive and 40% negative, which is a good start. However, in 42% of cases where workers felt negatively, fear of job loss was the reason.
They didn’t only fear losing jobs themselves, though. Some felt upset about the future of their livelihoods and the effects on future generations, envisioning a time not too long away when machines do most of their work.
Inadequate training was the second-biggest concern expressed by workers, accounting for 35% of the negative sentiments. More specifically, people worried they wouldn’t get well-equipped to succeed in increasingly digitalized workplaces. Some participants recognized robotic warehouse systems would reduce their workloads and the associated risks. However, their issues centered on not knowing how to handle the robots and the associated learning curve — especially for older workers.
Finally, other people expressed concerns about the technology failing, leaving people with no way to complete their work. The fears in this study are all valid and there’s no simple solution to address them all.
Supporting Workers While Encouraging Them
Warehouse leaders should start by being as transparent as possible about what bringing robots to the workplace will mean for employees. Focus on the positives while remaining open to hearing about anything that makes employees feel uneasy for any reason.
It’s also vital to schedule enough training so people will feel comfortable around the robots and learn to work productively with them. Be sensitive to how people may need more or less training depending on their current tech backgrounds. Clarify what they should do if the machines malfunction and discuss any related third-party tech support options. When people know which actions to take when things go wrong, they can replace feelings of uncertainty with preparedness.
Finally, recognize and empathize with how most humans feel anxious about changes at first. Give employees at least one contact person they can get in touch with at any time if they’re worried, struggling with new duties or having other issues. Praise employees’ willingness to try new things and celebrate victories — no matter how small — with them.
Designing an Appropriate Layout
Robotic warehouse systems need enough space to function correctly. Options such as autonomous mobile robots are highly compact and the machines usually have built-in technology to allow them to steer around obstacles.
However, an automated storage and retrieval system is a significantly more involved possibility that requires enough room for tracks and a shuttle or crane. These setups efficiently move goods to the right places in preparation for shipment. The systems work best in warehouses with items stored densely in a vertical orientation.
No matter what kind of robotic technology you consider or use, it’s always necessary to remember the space requirements of any other equipment you have. Otherwise, implementing something new could cause traffic bottlenecks or safety issues.
For example, if your facility uses counterbalanced forklifts, those machines need aisle widths of at least 12 feet when carrying 48-inch pallets. However, models like swing-mast and narrow-aisle forklifts can move safely through significantly smaller aisles.
Consider building a digital twin to test different warehouse layouts before trying them in real life, especially if you plan on making significant changes or constructing a new facility or extension to align with your robotics goals. The main advantage of a digital twin is it enables the simultaneous studying of complex systems and processes. People can save money and time by using one because they can see the outcomes of specific strategies in advance.
Statistics indicate companies spend an estimated $350 billion annually on warehousing. Technologies like digital twins can support intelligent expenditures that help robot-related initiatives go smoothly. Relatedly, if those with budgetary authority see robots will make warehouse operations more efficient via digital twins, they may be more open to tech upgrades.
Securing Executive Buy-In for Robotic Technologies
Although there’s a lot of buzz surrounding robotic warehouse systems, many leaders still consider them an emerging technology. One 2022 study found less than 30% of respondents currently use robots.
Elsewhere, coverage from Accenture revealed leaders often view automation’s potential too specifically, such as to solve a single problem or make one process more efficient. However, that approach may prove too limiting, convincing decision-makers that investing in robotic warehouse systems wastes time and money.
Accenture’s researchers recommend exploring opportunities to combine legacy and new technologies instead of being overly hasty to find quick wins. Relatedly, the study indicated many companies only reap incremental efficiency gains because those implementing the technology fail to emphasize scalable solutions.
These challenges can collectively make it more difficult to get executives to approve robotic technology expenditures. However, showing them case studies where peers have achieved great results with methodical approaches should pay off by increasing their confidence.
Robotic Warehouse Systems Support Growth and Goal Achievement
Using new technologies often comes with challenges. However, the solutions above can make obstacles less prominent and show people that warehouse robotics are accessible and feasible options.
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