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Warehouse automation:
A phased approach for smarter operations
Imagine a warehouse that practically runs itself. Inventory moves seamlessly, errors are minimal, and operations keep pace with demand. This is the promise of warehouse automation, which uses technology such as robotics, automated storage systems, and intelligent software to optimise the flow, storage, and management of goods.
Businesses are increasingly adopting warehouse automation to boost efficiency, cut costs, and improve accuracy. By reducing manual tasks and human error, warehouses can handle higher volumes faster and more reliably. The global warehouse automation market was estimated at over $23 billion in 2023 and is projected to surpass $40 billion by 2027, reflecting widespread adoption of these technologies.
Rather than overhauling everything at once, a phased approach often proves more effective. It allows companies to adapt processes, train staff, and integrate warehouse automation technologies without disrupting daily operations.
Why a phased warehouse automation approach works
“A gradual approach to warehouse automation is safer for operations, gives people time to adapt, helps you learn what works, and ensures efficiency gains are real and sustainable,” says Franco Ziccardi, Solution Design Transformation Director at Unipart.
Minimising disruption
Phased implementation ensures daily warehouse operations continue without interruptions. Businesses can maintain order fulfilment and customer service while introducing warehouse automation in manageable stages. Rushing full-scale automation can create bottlenecks, increase errors, and confuse staff, disrupting workflows and reducing efficiency.
Spreading investment and reducing financial risk
Phased adoption allows organisations to start with smaller, targeted investments in warehouse automation. This approach reduces financial pressure, supports better budget planning, and lets companies expand automation gradually as benefits become evident. “Starting small allows businesses to see real results before committing further, reducing financial risk and giving them confidence to scale up successfully,” adds Franco.
Supporting employee adaptation and upskilling
Introducing warehouse automation in stages gives employees time to become familiar with new technologies and processes. Facilities that implemented structured training programs and clear career progression pathways experienced 2.7× higher productivity, 43.6% greater employee satisfaction, and 47.6% higher retention rates during the transition. Gradual upskilling helps workers feel confident and more willing to embrace change.
Testing and refinement
Phased rollouts let organisations identify and resolve issues early rather than facing problems across an entire facility at once. Research shows staged deployments reduce workforce disruptions by 37.2% and improve system reliability by 28.6%. This approach supports continuous workflow optimisation, maximises efficiency at each stage, and ensures automated systems are fully ready before scaling up.
A guide to successful warehouse automation implementation
Based on our experience working with customers across a wide range of sectors, we have developed a flexible, phased approach to implementing warehouse automation that supports efficiency, improves adoption, and ensures every stage delivers measurable value.
Phase 1: Assessment & foundation
Begin by reviewing current operations, workflows, and pain points to understand where automation will create the greatest impact. Set clear objectives – whether enhancing accuracy, increasing capacity, improving visibility, or supporting faster fulfilment. Introduce scalable technology and adaptable infrastructure that can grow with the business. Early engagement with colleagues helps build awareness and gives people confidence ahead of the transition. Unipart tools such as the Digital Enterprise System (UDES) establish a strong base for inventory visibility, stock management, and process standardisation.
Phase 2: Pilot & early automation
Select a focused area or individual site to trial initial automation, such as picking, inventory control, or conveyor-based movement. Where appropriate, this may include the introduction of AMRs (Autonomous Mobile Robots) to support picking and material flow, particularly in retail and e-commerce environments. Pilot activity allows organisations to measure performance, refine workflows, and validate return on investment before expanding further.
Supporting colleagues with structured training and ensuring alignment with warehouse management systems helps adoption run smoothly. Sustainability considerations can also be embedded at this point, using live operational data to reduce waste and enhance efficiency.
Phase 3: Expansion & integration
Once early automation demonstrates clear benefits, extend these capabilities across additional processes or locations. Integrate technologies such as robotics, automated storage and retrieval systems, and AI-led optimisation to create connected, end-to-end visibility. Ensuring seamless interoperability between digital tools and existing IT systems helps build an integrated, efficient operation as automation expands.
Phase 4: Continuous improvement & future readiness
Use data generated from automated processes to drive ongoing improvements and review performance against key measures. Remain open to emerging technologies, including AI, IoT, smart contracts, and digital twins, so that the operation can evolve as capabilities grow. Encourage a culture of innovation and adaptability, ensuring colleagues feel prepared to adopt new tools and ways of working. Embedding both operational and sustainability insights into day-to-day routines helps secure long-term efficiency and supports broader environmental objectives.
“Taking a phased approach ensures that technology is introduced thoughtfully and that teams are prepared at each stage. It’s not just about the tech; it’s about people adapting and processes evolving together,” adds Franco.
Key considerations for success
Successfully implementing warehouse automation is about more than just technology, it’s about people, processes, and clear objectives.
Franco comments: “Technology alone won’t deliver results. The key to successful warehouse automation is aligning systems with your people, processes, and objectives. When teams are engaged and prepared, the benefits of automation multiply.”
- Involve staff early and support training: Engaging employees from the start builds buy-in and reduces resistance to change. Ongoing support ensures staff can confidently use new systems and contribute to continuous improvement.
- Align automation with business goals: Warehouse automation should directly support organisational objectives, whether increasing speed, reducing costs, improving accuracy, or enhancing customer service. Clear alignment ensures investments deliver tangible value and reinforce strategic priorities.
- Measure results and adjust at each stage: Tracking performance at every phase is critical. Monitoring outcomes, identifying bottlenecks, and making adjustments helps refine processes before moving to the next stage.
- Avoid common pitfalls: Rushing adoption without piloting, neglecting workforce engagement, choosing technology that lacks scalability or integration, or focusing solely on short-term savings can limit the success of warehouse automation. Being mindful of these risks ensures smoother, more effective implementation.
Take the first step
Warehouse automation doesn’t have to be an all-or-nothing decision. A phased approach allows organisations to implement change gradually, reduce risk, and support staff as they adapt to new systems.
By starting small, learning from each stage, and building on successes, businesses can make warehouse automation a sustainable part of operations. Consider where your automation journey might begin, whether with simple technologies, integrated systems, or advanced solutions, and focus on practical steps that fit your organisation’s needs and pace.
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