Workers say warehouses need more tech to keep up with orders

Zebra Technologies just released its latest Warehousing Vision Study, and it’s clear that warehouse workers want more technology to help them do their jobs. In the study, “Elevating Every Move: The Formula for High-Performance Warehousing,” workers spoke up about the need for automation and the risks of falling behind.

According to the study, 63% of warehouse leaders plan to roll out AI software and augmented reality in the next five years. About 64% say they’ll spend more on modernizing their warehouses, and 63% have either sped up their upgrade plans or will by 2029.

This comes as warehouses are getting bigger and busier. Research from Interact Analysis says global warehouse space will grow by 27%, hitting 42 billion square feet by 2030. At the same time, warehouse labor costs are expected to climb 7% each year.

As order volumes rise, frontline workers say warehouses need to move faster to add technology and boost workforce capacity. The message is clear:

• 85% of workers said, “If my employer does not invest in technology to improve warehouse operations, we will not meet business objectives.”
• 74% said they’re wasting time on tasks that could be automated.
• 72% worry about safety on crowded warehouse floors, and 70% are specifically concerned about injuries.
• 69% said there aren’t enough trained workers, and many are worried about fatigue and burnout.
• Even warehouse leaders admit they’re struggling to hit service level agreements (SLAs), with 51% saying fill rates are tough to maintain and 47% having trouble preparing orders. E-commerce is pushing demand even higher, adding pressure for faster delivery.

Workers say the technology would make a big difference. In fact, 88% said collaborative robots would help, and the same number wanted ergonomic mobile devices. About 87% said communication apps would help, and 91% wanted better task management tools.

In addition, 93% of workers said automation and mobile tech would make the job more appealing to new hires. And 89% said they feel more valued when they have good technology to work with.

“Warehouse associates are telling us they feel their lives would be better if their employers thoughtfully integrated more automation solutions into their workflows,” said Andres Boullosa, Global Warehouse Vertical Strategy Leader at Zebra.

Leaders also see the upside of using AI. According to Zebra’s study, 79% believe AI can improve safety by spotting hazards, 78% think AI can help catch errors, and 77% say AI can help forecast inventory needs and make better use of space.

Many leaders hope automation will reduce errors (71%), help them meet SLAs (70%), and boost productivity (54%). Another 53% want to reduce manual picking.

“Frontline workers are being asked to do so many things, including tasks they don’t even like doing — and those could and should be automated today,” Boullosa added. “It’s good to hear so many warehouse leaders plan to digitize, automate, and add intelligence to their frontline operations, and we are here to help.”

Regional Highlights:

• In Asia-Pacific, missed SLAs are a serious financial hit for 88% of decision-makers.
• In Europe, 73% of workers worry about getting hurt at work.
• In Latin America, 70% of leaders say avoiding errors is the main reason they’re adding automation.
• In North America, 88% say adopting new tech is essential to stay competitive.