Once considered too costly or complicated, automation is on the upswing, spurred by warehouse challenges such as a shrinking labor pool, warehouse worker turnover and increasing labor costs.
According to recent figures from the U.S. Bureau of Labor Statistics, the warehouse worker turnover rate reached 49 percent in May 2023, and labor costs increased 4.1 percent in the 12 months through June 2024.
Compounding labor challenges is a global retail e-commerce market that is expected to total $6.38 trillion U.S. dollars by the end of 2024, with projections showing that figure surpassing eight trillion dollars by the end of 2027.
The struggle to fill jobs has created a take-what-we-can-get approach among many hiring managers in manufacturing, warehousing and distribution. And as many companies turn to temporary staffing and third-party contractors to meet the demand for workers in material handling, ineffective training and the lack of operating experience are creating high-risk work environments, safety managers say.
Often portrayed as an adversary to workers who feared being replaced, automated technology today is perceived as an ally that can make their jobs easier, more fulfilling and safer, according to a survey of 500 U.S. warehouse workers commissioned by Lucas Systems.
Lucas Systems’ Voice of the Warehouse Worker Insights found that technology is a critical driver in employee attraction and retention, with 74 percent of respondents saying they were willing to trade pay for better technology tools to do their jobs.
One of the study’s most impactful findings shows that 90 percent of respondents believe investment in new technology will help attract and retain workers rather than create a fear of replacement.
And 88 percent said they believe that investing in automation is an investment in the company’s workforce.
In addition to bottom-line benefits such as higher productivity and increased profits, automated solutions have inherent benefits such as less physical exertion that leads to increased personal safety, greater job satisfaction and less staff turnover.
Eliminating risk factors
According to The National Institute for Occupational Safety and Health, the three leading causes of work-related injuries seen in emergency departments are:
- Contact with objects and equipment
- Overexertion and bodily reaction
- Falls, slips and trips without a fall
The U.S. Bureau of Labor Statistics lists the most common causes of nonfatal workplace injuries as:
- Overexertion and bodily reaction
- Falls, slips and trips
- Contact with objects or equipment
- Violence and other injuries by persons or animals
- Transportation accidents
Protecting the health and safety of workers through improved ergonomic design has been a focus of material handling equipment manufacturers for the past several years. For example, adjustable seats, seat-side hydraulic controls, rear-assist grip and horn, and tilting steering columns have become common lift truck features.
Automation solutions such as conveyor and sortation systems, automated storage and retrieval systems, pallet shuttles and automated guided vehicles (AGVs) take the reduction of ergonomic risk factors to an even higher level by eliminating tasks such as bending, reaching overhead, performing repetitive motions and lifting, pushing and pulling heavy loads.
The 2022 Lucas Systems study asked warehouse workers which types of technology they believe would best provide relief from the physical and mental strains of warehouse work. The results appear in the graphic below.
As more companies turn to automation solutions to meet hiring and production demands, more workers are beginning to see automation as a benefit. The Lucas Voice of the Warehouse Worker Insights study revealed that three out of four survey respondents believe that automation, especially workplace robots, may help them in their jobs in the following ways:
- Reduces my physical stress, 46 percent
- Helps me achieve better speed in item picking, 44 percent
- Helps me achieve better accuracy in item picking, 40 percent
- Allows me to do more satisfying work, 38 percent
- Assures my safety by taking over dangerous tasks, 37 percent
- Reduces my mental stress, 32 percent
Automation can cover everything from a simple conveyor to more complex systems that require integrated software and electronics. In addition to handling customers’ lift truck needs, Carolina Handling operates in a consultative manner, providing engineering and data-driven solutions to help customers refine their processes and find solutions.
For more information on how automation can address labor challenges and workplace safety, download our whitepaper, Labor Shortages and Workplace Safety: How Automation Can Help.
Go HERE for more information on automation solutions from Carolina Handling.
