How Automation is Making Warehouse Jobs Safer

Automated fulfillment solutions address safety challenges head-on.

By: Kari Miikkulainen, Contributor

Cimcorp’s order fulfillment solutions combine robotics technology and intelligent software for increased efficiency and throughput. Image courtesy of Cimcorp

In the fast-paced world of warehouse and distribution center (DC) operations, employee safety and well-being is a critical concern. Traditionally, these environments have relied heavily on manual labor, often requiring employees to perform physically demanding tasks like lifting and carrying heavy crates of goods, posing risks of injury and unhappy workers.

Luckily, today modern automated order fulfillment solutions are revolutionizing warehouse operations by addressing these challenges head-on. These technologies are not only helping to fill labor gaps and automate labor-intensive tasks, but also significantly reduce the risks of employee injuries and exertion.

While some have concerns about automation replacing jobs, a study¹ by the World Economic Forum found that by 2025, automation and a new division of labor between humans and machines will disrupt 85 million jobs globally, while also creating 97 million new roles. Here are several ways automation is facilitating the shift to a technology-focused workforce:

1. FILLING LABOR GAPS

One of the primary reasons distributors turn to automated order fulfillment solutions is their ability to fill critical labor gaps within warehouse operations. With ongoing labor shortages affecting industries worldwide, warehouses are increasingly turning to these solutions to maintain productivity levels and meet customer demand.

Automated order fulfillment solutions combine robotic technologies and intelligent software to handle repetitive tasks that would otherwise require extensive manual labor. By reducing dependency on human workers for these mundane tasks, warehouses can focus on continuous operations, and less impact of labor shortages on productivity.

2. ELIMINATING LABOR-INTENSIVE TASKS

Manually handling heavy loads has been a long-standing concern for warehouse workers due to the associated risks of workplace injuries like strains and sprains. Automated solutions mitigate these risks by automating labor-intensive tasks like lifting, carrying, and repetitive movements.

Gantry robotics and conveyor systems streamline the movement of goods throughout the warehouse, eliminating the need for employees to engage in physically demanding activities. This not only enhances workplace safety, but job satisfaction and employee retention.

Working Safely with Robots

The on-going introduction of advanced industrial, professional service and collaborative robots working alongside of human workers requires occupational safety and health professionals to take a proactive approach to the assessment and management of the risk profile of occupational robotics. To ensure that human workers are protected, the following measures are recommended for occupational robotics:

1. Occupational safety and health professionals should be directly involved in the development of international standards aimed at ensuring safety of workplaces with human and robot workers.
2. Workplace safety standards for maintenance, operation and interaction with human workers, of professional, personal service and collaborative (including managerial) robots should be developed.
3. Proactive approaches for establishing risk profiles of robotic workplaces should be developed.
4. Redundant safety measures should be developed and operationalized to protect human workers while performing maintenance tasks on robot workers.

Adapted from a National Institute for Occupational Safety (NIOSH) Science blog post (https://bit.ly/3A7tLtm) by Vladimir Murashov, PhD; Frank Hearl, PE; and John Howard, M.D.

3. ENHANCING SKILLS

Automation not only alleviates the physical burdens of labor but also enables employees to transition to safer, technology-focused roles within the warehouse environment. Skilled workers can transition to a role that oversees and manages the automated systems, perform maintenance tasks, and analyze data-driven insights to optimize warehouse operations.

This shift both enhances employee engagement and job satisfaction by empowering workers with valuable technical skills and responsibilities. Additionally, automation experience future-proofs workers roles in an increasingly automated industry, offering opportunities for career advancement and professional growth.

REAL-WORLD EXAMPLE

Fresh fruit and vegetables can only stay fresh for a limited time, and if there are any delays in delivering them, they can spoil or lose their nutritional value. Mercadona aims to guarantee the freshness of perishable fruit and vegetables for its customers. One of the best ways to do this is by reducing the lead time in its warehouses, thereby extending the shelf life of its products. With a commitment to providing high-quality produce and exceptional value for customers, Mercadona sought to optimize its order fulfillment process and minimize food waste.

So, Mercadona turned to automation. Today, with an automated material handling solution, Mercadona benefits from less waste and a safer workplace. By leveraging automatic storage, handling and order-picking capabilities in different temperature zones, Mercadona has streamlined its processes and reduced order-processing time significantly, enhancing product freshness and customer satisfaction.

RESHAPING THE WORKFORCE

Warehouse automation is reshaping the workforce by replacing repetitive and physically demanding manual tasks like picking, packing, and transporting goods. This shift allows human workers to focus on higher-value activities like improving operations, technology, and processes while minimizing the risks of injuries associated with manual labor. Additionally, automation offers opportunities for upskilling and career development in emerging technologies, ensuring that employees are equipped with the skills and knowledge needed for the evolving demands of the industry. WMHS

Kari Miikkulainen is Director of W&D Industry Sales for Cimcorp. Cimcorp offers a comprehensive range of automated solutions—including automated storage and retrieval systems (AS/RS), picking and sortation, automated guided vehicles (AGVs), and a Warehouse Control System (WCS)—that enables companies to tackle their biggest warehousing and distribution challenges, like energy efficiency, waste, and overall supply chain operations. Learn more at https://cimcorp.com/.