Warehouse Automation Support
Automation programs don't fail because the equipment is wrong. They fail because WMS integration is fragile, throughput doesn't meet design specs, exception handling breaks operational flow, and teams aren't prepared for the operational shift automation demands.
Warehouse automation represents a fundamental shift in how operations function. Whether it's AMRs, goods-to-person
systems, AS/RS, micro-fulfillment centers, or sortation, the technology is impressive but the integration and
adoption challenges are real. Organizations invest millions in automation expecting immediate returns, then struggle
when WCS and WMS don't communicate properly, when manual processes still bottleneck throughput, and when operators
resist the change.
BaszGroup supports organizations through automation planning, WMS/WCS integration, performance optimization,
change management, and recovery when automation programs underdeliver on their promise. We help bridge the gap
between equipment capability and operational reality.
Understanding Warehouse Automation Options
Autonomous Mobile Robots (AMRs)
Collaborative robots that navigate warehouse floors, bringing products to pickers or moving inventory between zones. Examples include Locus, 6 River Systems, inVia. Lower capital investment, flexible deployment, but requires floor space and traffic management.
Goods-to-Person (G2P) Systems
Dense storage with automated retrieval bringing bins or totes to ergonomic pick stations. AutoStore, Shuttle systems, VLMs. High throughput, space-efficient, but significant capital and infrastructure required.
AS/RS (Automated Storage and Retrieval)
Large-scale pallet or case storage with automated cranes. Dematic, Honeywell, TGW. Ideal for high-volume replenishment and reserve storage. Requires significant facility investment and long lead times.
Micro-Fulfillment Centers (MFCs)
Dense, automated facilities in urban areas for rapid grocery or retail fulfillment. Combines G2P, AMRs, and sortation. Takeoff, Fabric, Alert Innovation. High complexity but enables same-day or 1-hour delivery.
Sortation and Conveyor Systems
Automated sorting for order consolidation or shipping. Cross-belt, tilt-tray, sliding shoe sorters. Critical for parcel and ecommerce operations. Throughput capacity must match peak volume or creates bottlenecks.
Pick-Assist Technologies
Voice picking, pick-to-light, vision systems, collaborative robotic arms. Lower cost entry point for automation, improves manual productivity and accuracy. Often the first step before larger automation investments.
Industry-Specific Automation Drivers and Challenges
Consumer Packaged Goods (CPG)
High SKU count, promotional variability, multi-channel fulfillment. Automation focus is G2P for ecommerce picking, AS/RS for pallet storage, and sortation for order consolidation. Challenge is balancing automation with promotional flexibility.
Learn more about CPG programs →Grocery & Food
Temperature zones, expiration management, rapid fulfillment windows. MFCs and AMRs enable same-day grocery delivery. Challenge is cold chain automation and FEFO picking integration with WMS.
Learn more about Grocery programs →Industrial & Manufacturing
Raw material handling, component kitting, finished goods storage. AS/RS for heavy items, AMRs for line feeding, pick-to-light for kitting. Challenge is coordinating automation with production schedules and JIT delivery.
Learn more about Industrial programs →3PL & Logistics Providers
Multi-client operations, variable volume, diverse SKU profiles. Automation must be flexible enough to handle different client requirements. Challenge is achieving ROI when volume fluctuates and client mix changes.
Learn more about 3PL programs →Where Automation Programs Break
WMS and WCS integration is fragile or incomplete
- Handoff between WMS and WCS (Warehouse Control System) breaks under exceptions
- Inventory visibility lags, creating picking errors and allocation problems
- Task prioritization doesn't flow from WMS to automation properly
- Error recovery workflows aren't designed, so manual intervention is constant
- Real-time feedback loops (bins full, equipment down) don't trigger WMS adjustments
Throughput doesn't meet design specs
- Automation performs at 60 to 70% of promised capacity in real operations
- Manual processes upstream or downstream create bottlenecks
- SKU velocity and order profiles don't match design assumptions
- Peak volume surges overwhelm automation, forcing manual fallback
- Maintenance windows and unplanned downtime reduce effective capacity
Exception handling and error recovery are manual
- Automation stops when encountering damaged inventory or misplaced items
- No clear escalation path for exceptions, creating operator confusion
- Manual intervention zones aren't ergonomically designed or staffed properly
- Errors compound because root causes aren't identified and fixed
- Quality control checkpoints slow throughput instead of being integrated smoothly
Operator adoption and change management fail
- Workforce wasn't prepared for the shift from manual to automated operations
- Training focused on equipment operation, not exception handling or optimization
- Job roles and responsibilities weren't redesigned for automation
- Operators bypass automation when it slows them down or creates frustration
- Metrics and incentives still reward manual productivity, not automation utilization
Maintenance and uptime aren't managed proactively
- Preventive maintenance schedules conflict with operational needs
- Spare parts inventory and supplier support aren't established
- Equipment downtime isn't tracked or analyzed for root cause
- Vendor support SLAs are unclear or not enforced
- In-house maintenance expertise wasn't developed before vendor handoff
ROI and performance tracking are weak
- Throughput, accuracy, and labor savings aren't measured systematically
- Total cost of ownership (energy, maintenance, software) isn't tracked
- Business case assumptions aren't validated against actual performance
- Continuous improvement mindset is missing, so performance plateaus
- Automation utilization metrics don't exist, so idle capacity is invisible
Automation Program Struggling to Deliver?
If your automation investment isn't meeting throughput targets or ROI expectations, we help organizations optimize integration, operations, and adoption.
Measurable Success in Automation Programs
- Throughput reaches 85 to 95% of design capacity within 6 months
- WMS and WCS integration is stable with automated error recovery
- Exception handling is designed into workflows, not reactive
- Operator productivity improves as teams shift from manual to automation support
- Picking accuracy increases to 99.5%+ with automation-assisted operations
- Labor costs per unit decrease while service levels improve
- Equipment uptime stabilizes at 95%+ with proactive maintenance
- Peak season volume is handled without manual fallback
- Automation utilization is tracked and optimized continuously
- ROI timeline is met or exceeded as operations mature
- Workforce embraces automation as operational maturity improves
- Continuous improvement culture drives ongoing optimization
Where We Engage
We support warehouse automation programs from planning through optimization and recovery. Our focus is WMS/WCS integration, throughput optimization, exception handling design, operator readiness, and performance tracking. We help organizations realize the value of automation investments by bridging equipment capability with operational excellence.
Pre Go-Live Automation Readiness
WMS/WCS integration design, workflow design for hybrid manual/automated operations, exception handling strategy, operator training and change management, testing strategy, and performance monitoring framework.
Go-Live Command Center + Ramp-Up Support
Hands-on support during critical startup window. Integration triage, throughput optimization, exception resolution, operator coaching, vendor coordination, and daily performance tracking.
Automation Performance Optimization
For automation that's live but underperforming. Root-cause assessment, WMS/WCS integration fixes, workflow redesign, throughput analysis, continuous improvement execution, and ROI realization tracking.
Program Recovery and Remediation
For automation programs that are stuck or failing. Comprehensive assessment, stakeholder alignment, integration corrections, operational redesign, vendor accountability, and sustained stabilization support.
Learn More About Our Automation Services
Ready to Talk About Your Automation Program?
Let's Realize Your Automation ROI
Whether you're planning an automation investment, struggling with integration and performance, or recovering from a difficult rollout, we can help.