Frontline workers communicated the benefits of automating warehouse operations and the risks of not automating fast enough, according to a new study released by Zebra Technologies Corporation.

The global firm known to digitize and automate frontline workflows released the findings of its latest Warehousing Vision Study.

The report, “Elevating Every Move: The Formula for High-Performance Warehousing,” found that 63 percent of warehouse leaders plan to implement artificial intelligence (AI) software and augmented reality (AR) within five years.

In addition, 64 percent plan to increase spending on warehouse modernization in the next five years, and 63 percent plan to accelerate their modernization timelines by 2029.

Feedback shared by frontline workers suggests that warehouse leaders will need to move a bit faster to expand workforce capacity and improve safety:

• 85 percent of associates say, “If my employer does not invest in technology to improve warehouse operations, we will not meet business objectives.”
• 74 percent of associates are concerned they are spending too much time on tasks that could be automated.
• 72 percent of associates are concerned about safety on the (increasingly busy) warehouse floor with 70 percent specifically worried about injuries.
• 69 percent of associates reported there is a lack of qualified staff on the warehouse floor and express concerns about fatigue and physical exhaustion.

Even warehouse leaders admit they find it challenging to maintain the fill rates (51 percent) and prepare orders (47 percent) outlined in their service level agreements (SLAs), with order accuracy and outbound processes cited as the top two operational challenges in the Zebra study.

Increased e-commerce activity is also making “faster delivery to the end-customer” a top challenge for warehouse teams, even as technology use is on the rise.

Given the disparity between customers’ growing expectations and warehouse operators’ limited hiring capacity, warehouse associates say it’s important that collaborative robots (88 percent), ergonomic mobile devices (88 percent), communications applications (87 percent), and task management tools (91 percent) are used to help solve workplace issues.

Ninety-three percent of associates agree the increased availability of automation and mobile technologies would help attract and retain more warehouse associates, and 89 percent say they feel more valued by their employers when provided with technology tools and automation designed to help them.

“Warehouse associates are telling us they feel their lives would be better if their employers thoughtfully integrated more automation solutions into their workflows,” said Andres Boullosa, global warehouse vertical strategy leader, Zebra Technologies. “Automating material movement, data collection, and information management helps make busy warehouses safer. It also makes it easier for teams to meet SLAs and maintain a steady, reliable flow of quality goods to the market, which increases both customer satisfaction and worker engagement.”

Warehouse leaders believe the biggest impact of mobile device-based AI applications will center on worker safety, quality control and inventory management.

While 79 percent say AI will positively impact their ability to detect potential hazards and issue alerts for prevention, 78 percent think AI would make an impact on their ability to detect issues or anomalies using AI.

In addition, 77 percent feel AI applications would impact their ability to forecast needs, streamline stock levels and maximize space using AI applications.

Many warehouse leaders who plan to augment/automate or have already done so say their goal is to mitigate errors (71 percent) and meet SLAs (70 percent).

They hope automation will increase worker efficiency and productivity (54 percent) as well as reduce order errors and manual picking (53 percent).

Plus, 82 percent of warehouse leaders agree giving warehouse workers more technology tools will help them exceed productivity goals while reducing physical strain and preventing injuries. Eighty-one percent of the leaders also admit automation improves morale.

Warehouse leaders say their biggest supply chain network challenges are “innovating with technology and intelligent automation” and “meeting changing customer service expectations.” Yet, the latter will not prove possible until warehouse leaders figure out a clear path forward with technology.

“There are so many things that frontline workers are being asked to do in warehouses, including things they don’t enjoy doing, which could and should be automated today,” added Boullosa. “It’s good to hear so many warehouse leaders plan to digitize, automate and add intelligence to their frontline operations, and we are here to help.”

Regional Findings:

Asia-Pacific: Missed SLAs are a tremendous financial burden for 88 percent of decision-makers, underscoring the need to swiftly address inefficiencies.
Europe: Workplace safety remains a concern, with 73 percent of associates worried about injuries on the warehouse floor.
Latin America: 70 percent of decision-makers who plan to augment/automate or have done so already say the biggest driver for automation is the need to mitigate errors.
North America: 88 percent of decision-makers agree adopting new technology is essential to remain competitive in the fast-paced, on-demand economy.