Warehouse Automation: Are You Building a Faster Disaster?

Warehouse Automation: Are You Building a Faster Disaster?

Everywhere you look these days, “automation” is the buzzword. It started with the automotive industry, and it trickled its way into nearly every part of daily life. The benefits of automation are undeniable: you can get more work done, you can usually get it done more quickly, it frees people up to work on other things, and it often eliminates dangerous tasks while contributing to a better work-life balance for all involved.

But what happens when automation goes awry? Sometimes—in the pursuit of efficiency and automation—some companies end up creating more problems than they set out to solve. Here’s how you can avoid creating a “faster” disaster.

The Danger of Bad Automation

Even though automation can be a total game-changer for your business, if you implement it incorrectly, you might inadvertently cripple your operations. If you’re not careful, falling for the pure allure of automation can blind you to all of the complexities involved in proper integration. For instance, if you invest in the wrong solutions, or if you deploy those solutions in the wrong way, you can land yourself in a mess of inefficiencies, increased costs, and operational headaches. This is what we mean by a “faster disaster.”

Consider the case of one major beverage manufacturer. Eager to enhance its production line, the company partnered with an OEM (Original Equipment Manufacturer) for an automation solution. However, what seemed like a well-planned strategy quickly turned into a logistical nightmare. The new system introduced over 15 touches within a mere 30 feet for a single beverage can. Each "touch" represented a point where the can was moved, inspected, or manipulated—a staggering waste of space, time, and resources. Instead of streamlining production, this automation debacle added unnecessary complexity and costs.

Why Does Automation Go Wrong?

There are several reasons why automation projects can fail, but most stem from a lack of strategic planning and the absence of a comprehensive integration approach. If you focus on automating specific tasks without considering the broader impact on the overall operations, you can unknowingly automate yourself into a scenario where you have a system that is highly efficient at one task but creates bottlenecks elsewhere.

This is why choosing the correct supplier and integrator is crucial. Not all automation solutions are created equal, and not every supplier has the expertise to tailor systems to your specific needs. The beverage manufacturer’s situation is a modern example of choosing the wrong partner. They ended up with an overly complex system that did not align with their operational goals, resulting in inefficiencies that could have been avoided with a more thoughtful approach.

The Importance of Choosing the Right Partner

So how can you avoid building a "faster disaster?" Stated simply, you need to select your automation partner wisely. Easier said than done. The right integrator should not only provide cutting-edge technology, but they should also take the time to develop a deep understanding of your unique operational challenges. They should work closely with you to design a system that enhances your processes, rather than complicating them. They need to be your consultant.

When selecting a supplier or integrator, consider the following:

1. Experience in Your Industry: Choose a partner with a proven track record in your specific industry. They will be more attuned to the common challenges and best practices. Unique needs require unique solutions. Avoid anyone trying to sell you a cookie-cutter approach.
2. Holistic Approach: Your partner should take a comprehensive approach to automation, looking beyond individual processes to understand how changes will impact your entire operation. A holistic approach like this ensures that your automation system integrates seamlessly with existing workflows—without creating bottlenecks elsewhere.
3. Customization and Scalability: Avoid one-size-fits-all solutions. The best automation systems are customizable and scalable. You want to set yourself up for the opportunity to grow your automation system with your business and adapt to evolving needs.
4. Transparency and Support: A reliable partner will be transparent about the potential challenges of automation and provide ongoing support to address any issues that arise post-implementation.

Turning Automation into an Asset, Not a Liability

Automation should simplify processes, reduce manual labor, and cut costs. But as the beverage manufacturer's case illustrates, implementing the wrong automation can lead to excessive complexity and inefficiency. To ensure your automation strategy drives real growth, it’s crucial to partner with experts who understand the nuances of your industry and are committed to designing solutions that work for you—not against you.

Remember: although automation can revolutionize your operations, it’s not a magic bullet. Careful planning, strategic partnerships, and a holistic approach are key. That’s why choosing the right integrator is so important. Don't let the promise of speed and efficiency lure you into a faster disaster. Instead, set yourself up for long-term success by choosing the right solutions and the right partners from the start.