Overcoming Common Warehouse Automation Challenges

The term “warehouse automation” describes the use of computers and other electronic devices to streamline and improve operations in a storage facility or distribution center. Robots, conveyor belts, and other automated technologies are often used to organize the warehouse and make it easier to store and retrieve goods.

Technology is used for this purpose as well, allowing for more accurate tracking and management of stock and better coordination and optimization of the movement of products and materials inside the warehouse. Warehouse automation aims to accomplish these things through facilitating smoother operations, decreasing the number of mistakes made, and raising output levels generally.

Why is Warehouse Automation the Right Choice?

Some of the advantages of employing warehouse automation include:

Increased Efficiency

Automated systems can handle tasks more quickly and accurately than humans, resulting in increased efficiency and productivity within the warehouse.

Reduced Labor Costs

Automation can help to reduce the need for manual labor, resulting in lower labor costs for the business.

Improved Accuracy

Automated systems can help to reduce the risk of errors in tasks such as sorting and storing items; improving the accuracy and reliability of the warehouse operations.

Increased Flexibility

Automated systems can be easily reprogrammed or reconfigured to handle different tasks or accommodate changes in the warehouse, which can increase the flexibility of the warehouse operations.

Improved Safety

Automation can help to reduce the risk of accidents and injuries within the warehouse, as automated systems can handle tasks that may be dangerous or physically demanding for humans.

However, while automated warehouses have many advantages, they are not a quick fix for any company. There are several challenges inherent to adopting and using automation tools. Although the payoff is substantial, it is worth your time to do the work.

Here are some of the most common warehouse automation challenges and some of the solutions that can help you overcome them, as well as the reasons why automation makes sense for your warehouse or distribution business.=

Common Warehouse Automation Challenges and How to Solve Them

Warehouse automation has evident advantages. However, there are risks involved with automation, especially during the installation phase. Automation experts at RTS have listed some of the most typical obstacles to warehouse automation below.

Challenges faced with Inaccuracy in Inventory

Inaccurate inventory can lead to a range of problems such as having too much or too little of certain products, or having excess inventory that is no longer needed. These issues can then lead to inefficiencies in picking and other processes, as well as reduced productivity, increased expenses, and lost revenue.


There are three approaches to fixing these issues, the first of which is the introduction of an automated inventory management system to aid with the provision of up-to-the-minute, accurate data on stock levels and types. This may assist keep the warehouse from stocking up on unnecessary or stale goods and ensuring that there is always enough inventory on hand to fulfill client demand.

Second, warehouse inventory monitoring and management may be automated with the use of barcode scanning or RFID (radio-frequency identification) technology. This has the potential to increase the reliability of stock count records by decreasing the number of recorded mistakes.

Finally, techniques for real-time data analytics may be used to help reveal previously unseen patterns in warehouse activity and stock levels. This may aid in optimizing the movement of products and commodities inside the warehouse by revealing patterns and trends in demand.

Challenges with Redundancy and Health Risk in Warehouse Operations

Since the introduction of Covid-19, warehouse workers have been warned against the practice of repeatedly handling products. When employees at a warehouse use multiple hands to process the same ticket, this is an example of a redundant procedure. This not only raises the price of labor, but also endangers workers’ wellbeing.


The use of barcode technology in warehouses is one solution to this problem since it allows for the simplification of processes, the removal of unnecessary steps, and the optimization of available resources. In order to succeed in today’s highly competitive industry, warehouse managers need to be abreast of the newest developments in automated technologies.

Challenges of an Ineffective Warehouse Layout

Companies today are under increasing pressure to increase output while decreasing costs, making efficient use of warehouse space more important than ever. Poor facility layout is a significant contributor to typical warehouse problems including insufficient storage space or the improper use of existing space. A warehouse’s profitability might be negatively impacted by a lackluster layout and layout.


Optimizing the warehouse’s layout in terms of floor space, vertical space, equipment, and manpower may help alleviate these issues. In addition to making everything easily accessible, a good plan should also guarantee the safety of employees and the security of stored goods. Using forklifts is a great method to make the most of the available horizontal and vertical space in your warehouse. Another option is to simplify the dock-to-stock procedure and put high-turnover items in highly visible places.=

Labor Cost Challenges

Successful warehouse managers seek to maximize output even as they work to cut down on labor expenses, which can eat up a sizable percentage of operating funds. Challenges at warehouses are sometimes magnified by the reliance on costly equipment and huge numbers of workers. Personnel at a warehouse can include cleaners, packers, managers, and office workers, among others.

RTS Labs is aware that the Covid-19 outbreak has presented new difficulties for warehouses, such as the need to modify shift schedules, implement social distancing policies, and manage logistical changes while supervising an uncertain staff.


Warehouses can tackle labor issues in a few different ways. They can do so by making the most of their current workforce or by switching to automated technologies. It’s crucial to think about how these tactics can affect other expenses. When managers engage in careful workforce planning, they are better able to determine what kinds of knowledge and abilities will be required to run an efficient and effective workplace.

Warehouse efficiency and output may benefit from a more motivated and supported staff, as shown by measures like better working conditions, training, and more adaptable scheduling.

Challenges with Optimized Picking

RTS Labs suggests that concentrating on the picking process is a straightforward and successful strategy to boost warehouse efficiency and, by extension, profits. Many issues that arise in warehouse management have their origins in picking, rather than in botched receiving or storage. If actions and choices are hurried to satisfy urgent client requirements in a high-pressure setting, it might disrupt inventory management.


Many warehouses are switching to voice-directed and radio-frequency systems to solve this problem, but others, especially those with fewer employees, depend on paper-based methods. Maintaining strict adherence to the selected system is crucial, no matter how difficult it may be under the given conditions. Verifying the accuracy and dependability of master data is essential for keeping the system running smoothly.

Keeping an accurate inventory record requires noting any deviations from the norm, such as the provision of a replacement item or the discovery of the wrong item in a slot. Another common source of picking mistakes is discovering an item has been overproduced but is unavailable due to being held for back orders.

Quality Control Challenges

Workers that are responsible for quality control sometimes also manage selecting, packaging, and shipping of inventory products, increasing the likelihood that mistakes may go unnoticed until they reach the client. During a pandemic, when warehouses are rushing to transport more with less workers, this is a regular occurrence.


Having a distinct quality control level to enhance inventory management and supply chain procedures is the best solution to this problem. Having a dedicated layer of control over inventory concerns may provide the push needed to handle routine problems in a methodical, responsible manner.

It is possible to keep track of vendor precision, increase the efficiency of stock rotation, and lessen the workload of warehouse workers by using a quality control system. These systems also verify that the remainder of the warehouse management software is operating as it should.

There are four main components to warehouse management, but the underlying processes are dynamic and complicated, and they may be influenced by international politics. Warehouse managers in all sectors and all parts of the world have been adversely affected by this new environment. Because of resource and logistical constraints, distributors have had to make sacrifices, resulting in subpar performance in crucial operational areas and an uphill battle for continued relevance and viability.

An all-encompassing framework is essential for overcoming obstacles. The more modern your WMS technology is and the more open and available your data is, the more you can minimize risks and have a consistent, reliable warehouse that your employees and customers can have faith in.


Warehouse automation is a potent tool that may provide companies a competitive edge in today’s dynamic industrial landscape. While implementing and managing warehouse automation can be challenging, following these tips can help your company increase efficiency and avoid common pitfalls.

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