Mechanisation or robotisation: automating your warehouse to boost performance

62% of consumers expect their orders to be delivered within three working days. This creates a significant challenge for warehouses still dependent on manual processes. To meet these growing demands, warehouse automation has become essential. But how do you determine the right technology for your needs? What are the key differences between automation, mechanisation, and robotisation? Here’s a clear overview to guide you in making an informed decision.

Warehouse automation in logistics involves the adoption of advanced systems and technologies to replace or enhance tasks traditionally carried out by human operators. This shift results in less manual handling, faster processing times, and greater accuracy in stock management.

The field of logistics warehouse automation has advanced significantly in recent years, incorporating both traditional warehouse mechanisation and innovative warehouse robotisation. Regardless of the approach, automation delivers immediate benefits: it shortens order processing times, accelerates repetitive task production, enhances stock accuracy, and maximises space utilisation.

For operators, automation improves workplace safety and enhances quality of life by minimising the need to handle heavy or hazardous goods.

For businesses, it reduces error rates and decreases returns, leading to measurable cost savings.

Warehouse mechanisation marked the beginning of automation with tools such as forklifts, pallet trucks, and conveyor belts—devices designed to ease physical labour.

This equipment has made it possible to entrust machines with specific tasks previously carried out by operators, such as lifting heavy loads or transporting storage units through the warehouse aisles.

Over time, more advanced mechanised warehouse systems like Automated Storage and Retrieval Systems (AS/RS) emerged. These include shuttles, cranes, and lifts that manage repetitive tasks such as moving goods from storage shelves to order preparation stations. By replacing manual labour with mechanised systems, businesses achieved better warehouse management, faster order fulfilment, and more accurate inventory control.

A notable advancement in logistics warehouse automation has been Good-to-Person (GTP) systems. These deliver goods directly to workstations, eliminating the need for operators to walk through aisles—a time-consuming task prone to human error.

Today, mechanised warehouse systems are no longer optional; they’re a baseline requirement. However, to unlock the full potential of automation, businesses must explore warehouse robotisation.

Warehouse robotisation goes beyond physical assistance, integrating advanced robotics capable of performing both physical and cognitive tasks. The robots, equipped with mechanical, electronic, software, and artificial intelligence components, are capable of processing environmental data and making autonomous decisions.

This marks a significant leap in logistics warehouse robotisation, where machines are no longer limited to repetitive tasks but can adapt dynamically to their surroundings.

Robotic Automated Storage and Retrieval Systems (AS/RS) provide unmatched flexibility and scalability. Unlike conventional mechanised solutions, robotic systems are designed for seamless expansion—additional robots or racking can be integrated without disrupting ongoing operations.

For instance, Exotec’s Skypod system exemplifies the power of robotic warehouse automation. These robots navigate autonomously and vertically along storage racks at speeds of up to 4 m/sec, a rate that is five times faster than manual processes. This capability enables same-day order fulfilment, a transformative advantage in the logistics sector.

While automated warehouse systems are becoming indispensable, their implementation comes with challenges. The initial investment may seem high, but the long-term savings through reduced labour costs and optimised storage make automation a cost-effective solution.

System integration also requires careful consideration. Modern warehouse automation technologies ensure seamless communication with existing equipment, but compatibility must be rigorously assessed.

Supporting operators through training and consistent communication ensures the smooth adoption of new systems.

Implementing automation, whether through mechanisation or robotisation, requires careful planning and strategic decision-making to select the most suitable solution. Here’s how to approach it effectively:

• Assess Your Needs: evaluate the impact of automation on your operations. Is mechanisation sufficient, or would robotisation deliver greater efficiencies? Consider factors like throughput, order volume, and site-specific constraints. Don’t forget to weigh investment capacity against the potential savings automation can generate.
• Prioritise Flexibility: choose solutions that can grow with your business. For instance, robotisation offers unparalleled adaptability to evolving warehouse demands, ensuring long-term scalability.
• Develop a Change Management Plan: no matter the automation path you choose, a well-structured change management plan is essential. Involve stakeholders at every stage and provide comprehensive support to help your teams adapt. This collaborative approach fosters commitment and ensures the smooth adoption of new technologies.

For a truly sustainable solution, focus on gathering consolidated data on order volumes, item dimensions, and seasonal fluctuations. These insights are crucial for optimising your warehouse and can help build a strong case for robotisation. Unlike traditional mechanisation systems, robotic solutions are inherently more flexible, adapting seamlessly to your business needs while continuously enhancing performance.

Finally, implement a phased roll-out strategy. Regularly evaluate and adjust processes to ensure a controlled and efficient transition to automation.

Would you like to take your warehouse productivity to the next level? Explore our Skypod solution with a virtual tour and discover how it can be tailored to your unique requirements.