When you’re building a new warehouse, you can integrate automation from the ground up without any disruption. But for existing warehouses — also known as “brownfield sites” — changes can impact output and revenue. To mitigate risks, it’s important to avoid rushing the process.

Here's a quick guide to implementing automation without disrupting your workflow, while minimizing costs and maintaining flexibility in a dynamic business environment.

Strategic, Staged Implementation

Instead of aiming for overnight automation, plan for gradual improvements. While it’s tempting to upgrade everything at once to boost throughput and cut costs, this can backfire. A large-scale implementation can cause significant disruptions or even shut down operations temporarily. Moreover, potential delays due to material shortages or shipping issues can pose additional risks.

Identify and Prioritize Bottlenecks

Begin by pinpointing the biggest bottlenecks in your operations. Sometimes, the issues aren’t where you expect. For instance, order pickers might seem slow, but the real problem could be the travel time needed for picking. Or, inventory inaccuracies might be due to too much human handling. By automating these areas first, you can see faster returns on your investment.

Plan for Uncertainties

Phased automation not only reduces operational risks but also spreads out capital expenses. It allows employees to gradually adjust to new processes, fostering acceptance and reducing resistance. Clear communication about the overall vision and phased approach helps the workforce adapt without feeling overwhelmed.

Staged implementation provides flexibility to adapt to changing business needs. Factors like demand fluctuations, regulatory changes, and labor availability can influence your operations. By automating in stages, you can evaluate and adjust your plans as needed.

Rely on Experts

Creating a fully automated facility is complex, and planning staged implementation adds another layer of complexity. Consulting with an integrator can provide valuable insights and assistance tailored to your facility’s specific needs.

Choose Flexible Automation

As your business evolves, so will your automation needs. It’s crucial to select systems that can grow with you. Look for technologies that are adaptable to various materials and environments, and be cautious of systems that require high-precision environments, heavy custom infrastructure, or limited container types. Truly flexible automation will continue to deliver value as your operations expand and change.

For more detailed guidance on identifying flexible automation and cutting costs, click below to download your copy of “How to Identify Flexible Automation and Use It to Cut Costs”.