A new industry report indicates that warehouses worldwide are undergoing rapid modernization, with robotics, automation, and advanced technologies playing a central role. The Warehouse Vision Study by Zebra Technologies surveyed over 1,700 associates and decision-makers across sectors such as manufacturing, retail, logistics, and wholesale distribution, highlighting the trends shaping warehouse operations over the next five years.
According to the study, warehouse operators are under growing pressure to increase efficiency and meet rising consumer demands. Seventy percent of decision-makers reported high pressure to modernize their operations, while 64% plan to increase funding for modernization initiatives within five years. Automation, including the integration of robotics and artificial intelligence (AI), is a key component of these efforts.
Robotic systems, particularly mobile robots, are increasingly being adopted to streamline tasks like picking, packing, and sorting. Seventy-one percent of surveyed decision-makers cited error mitigation as the primary driver for automation investments. By reducing manual handling errors, automation is expected to improve order accuracy and enhance operational visibility.
Refining operational workflows
The study found that AI technologies are also gaining prominence. Sixty-three percent of respondents plan to implement AI solutions within five years, with applications focused on inventory management, quality control, and safety hazard detection. Machine learning and predictive analytics are anticipated to play a growing role in forecasting demand, optimizing inventory, and refining operational workflows.
Despite these advancements, the modernization process presents challenges. Decision-makers identified determining the return on investment, replacing legacy systems, and managing service and support for new technologies as the top barriers to implementing warehouse automation. The report emphasizes that addressing these obstacles strategically is crucial for ensuring a resilient and efficient modernization process.
The human element remains an important factor in warehouse transformation. The study revealed that technology adoption is positively received by warehouse associates. Eighty-nine percent of associates surveyed reported feeling more valued when provided with technology tools and automation. In addition, 93% agreed that the adoption of modern technologies is essential for attracting and retaining talent. Modern devices such as wearables, mobile computers, and mobile robots are seen as critical tools for reducing physical strain and improving workplace productivity.
Augmenting labor with technology
The survey also found strong support among associates for the phased introduction of automation. Ninety-one percent agreed that augmenting labor with technology and devices first is the best way to introduce automation into warehouse operations. This suggests that a gradual approach, where human workers and technology collaborate, may facilitate smoother transitions and higher acceptance rates.
Decision-makers appear to recognize the importance of involving the workforce in technology decisions. Ninety percent of decision-makers reported involving associates in shaping automation strategies, a figure that has increased by 11 percentage points compared to the previous year.
Regional data showed a consistent trend across markets, with 93% of associates in North America, 92% in Asia Pacific, 93% in Europe, and 94% in Latin America supporting the introduction of technologies to attract and retain workers.
Looking ahead, the study projects that 63% of decision-makers plan to accelerate the timelines of their modernization projects by 2029. Strategic investments are expected to focus on AI-driven decision-making, workflow automation, labor optimization, and expanded visibility across warehouse and supply chain operations.
Safety risks
The Warehouse Vision Study concludes that modernization strategies that combine advanced technologies with a skilled workforce are likely to be most effective in achieving operational goals. As the pace of change continues to accelerate, the ability to integrate new technologies while supporting frontline workers will remain a key determinant of success in the warehousing sector.
In parallel with these trends, Exotec announced new automation solutions aimed at addressing warehouse safety concerns. Coinciding with the World Day for Safety and Health at Work on April 28, the company highlighted that 73% of European warehouse employees are worried about safety risks in increasingly busy environments, according to the Warehouse Vision Study.
Exotec sys its Skypod system is designed with a focus on worker safety, featuring autonomous robots that reduce human movement, ergonomically designed picking stations to minimize repetitive strain, and collision avoidance technologies. The company states that these measures aim to lower workplace injuries, improve employee wellbeing, and support more efficient operations as warehouse complexity continues to rise.
