Supporting Warehouses through Protective Innovation

By Kevin Ledversis, VP Sales, Newcastle Systems

Warehouse automation is on everyone’s mind in the industry, with conversations surrounding light-out warehousing on the rise—a concept where an entire warehouse is fully automated. While these ideas seemed decades away at first, automation is quickly becoming the future of the industry. Data from the Newcastle Systems 2025 Industry Report supports this trend, with 26% of warehouses planning to be automated by 2027. Rising pressures and an increased reliance on the supply chain have led many businesses to conduct internal audits of their operations, seeking areas to cut costs or increase efficiency. This approach tends to leave operations blind to issues within the organization, namely regarding the frontline workforce.

Many of the newest innovations in automation involve the total replacement of workers. While attractive at first glance, these solutions come with enormous upfront costs, as well as numerous other issues, such as retrofitting legacy systems and recalibration. A much more intangible yet important aspect that has fallen to the wayside in the wake of the automation arms race is company culture. Our employees are truly the engine of operations, consistently rising to growing expectations from internal and external pressures. Warehouse employment is down about 27,000 jobs year over year, according to the latest jobs report, with many employees fearful of uncertain business directions and replacement. As workers begin to spend more time in the warehouse under increasing pressures, morale and spirit are questioned, which ultimately affects the bottom line.

The warehousing environment requires a holistic approach, with employees in mind. Through the use of technology that supports employees, rather than replacing them, companies can begin to build loyalty and trust within their workforce. This frame of thinking also combats a majority of automation’s downsides. By considering the overall flow of work, management can begin to identify bottlenecks where support to existing operations can vastly improve not just turnaround times, but also the industry as a whole.

Technology that Supports, Not Replaces

The Sharpie company recently brought its manufacturing home to Maryville, Tennessee. This necessitated the inclusion of robotics and new processes that were previously handled overseas. Through a shift in mindset and the examination of emerging technologies, they found that the factory could utilize robots to perform an increasing share of the packing. Additionally, they kept the employees who knew the company and converted their jobs to supporting roles such as automation engineering. In that case, an employee would fix a robot instead of packing a box. Sharpie even created a career-training program so existing employees could learn the skills they needed for the new jobs. With additional investments in robots and training, the factory has been able to make pens at three to four times its previous speed, with better quality and higher employee satisfaction.

For warehousing, one of the processes most ripe for automation is picking. Picking often accounts for more than half of total labor costs, with order retrieval and fulfillment being key foundational aspects of processing. Recent trends indicate an increase in online orders and reliance on supply chains, accompanied by a rise in returns more than ever before. The pressure is on for organizations to streamline their picking processes, creating more efficient workflows that ultimately fuel growth. This mentality creates an environment of constant improvement, which can take a toll. Long hours and physical strain can increase the likelihood of errors and injuries, which significantly contribute to a poor company culture.

Sharpie serves as a powerful example of how supporting workers, and ultimately the processes they have been performing for years, can lead to increased productivity and efficiency, without compromising frontline employees. Taking a page out of their playbook, many manufacturers can look towards technology that improves everyday tasks, such as mobile-powered carts and ergonomic scanners, coupled with voice-picking technologies. Together, these technologies empower workers to complete tasks more efficiently with fewer errors, while allowing companies to avoid the upfront costs associated with more complex alternatives. These tools also foster a culture that employees can see and feel, through increased safety and comfort. While trainings and rulebooks create codes of conduct and standard operating procedures, it is through actionable decisions that support employees that most improve morale and ultimately efficiency.

Resilience Through Innovation

Overexertion and bodily reactions have recently been identified as the most prevalent hazards in the warehousing industry, surpassing even slips, trips, and falls. These injuries often result from repetitive motions and awkward postures, which, whether performed correctly or not, place constant strain on the body. Over time, this strain can lead to musculoskeletal disorders, including conditions such as tendonitis, carpal tunnel syndrome, and chronic back pain. Among the many physically demanding roles in a warehouse, order picking stands out as one of the most repetitive and injury-prone tasks. Pickers are often required to bend, twist, reach, and lift hundreds of times per shift, leaving them especially vulnerable to chronic injuries.

Initially, these small, often overlooked injuries may only result in temporary discomfort or a loss in productivity. However, if left unaddressed, they can compound and spread across teams, leading to increased absenteeism, higher turnover rates, and a generally unsafe working environment. In a time when warehousing employment is at an all-time low and labor shortages are impacting supply chains globally, protecting the existing workforce has become more critical than ever. The physical toll of the job, combined with its perceived lack of safety, continues to deter potential workers from entering the field, further widening the labor gap.

To address these challenges, modern warehouses are prioritizing ergonomic interventions and embracing technologies that reduce physical strain and improve overall working conditions. Hands-free technology eliminates the need for workers to carry clipboards, pens, or handheld scanners. This not only reduces cognitive load, allowing pickers to focus more clearly on accuracy and efficiency, but also enables them to maintain better posture and body mechanics throughout their shifts. With both hands free, workers can lift, reach, and move more naturally, minimizing the risk of injury.

By investing in technology that actively reduces physical strain and reshapes the narrative around warehousing as a dangerous or unsustainable profession, companies can create safer, more attractive workplaces. This shift is essential not only for protecting current employees but also for rebuilding a resilient, long-term labor force capable of meeting the growing demands of modern logistics.

Unlocking Modern Warehousing

The warehousing industry is evolving to meet rising expectations from consumers, investors, and leadership, often by streamlining operations and adopting new technologies. While these changes can spark concerns among workers about job security and the role of automation, they also present an opportunity to enhance and support the workforce. When implemented thoughtfully, technology can reduce physical strain, simplify tasks, and allow employees to focus on more meaningful work. By involving teams in the transition and providing the right training and support, organizations can foster trust and resilience. In doing so, innovation becomes a shared tool for strengthening both the workforce and overall operations.

About the Author

Kevin Ledversis is the Vice President of Sales at Newcastle Systems, a leader in mobile-powered industrial carts that help organizations like Walmart, UPS, Wayfair, and Tesla drive efficiency across warehouse, manufacturing, and retail environments. With over 30 years of experience in the Automatic Identification and Data Capture (AIDC) industry, Kevin is a trusted advisor to companies seeking to streamline operations through barcoding technology and lean practices. Lean Six Sigma certified, Kevin has served on regional boards for both the Association for Manufacturing Excellence and the Warehouse Education and Research Council, contributing to the advancement of best practices in operational excellence. Beyond driving growth, he champions Newcastle’s mission to elevate the role of frontline workers—most recently reflected in the company’s 2025 Newcastle Systems Industry Trend Report, which highlights the importance of the human element in the age of automation.