This guide explains what warehouse automation is, the main types available, and how to implement it step-by-step. You’ll also find a clear comparison of whether to automate your own warehouse with a WMS or outsource to a fulfilment partner.<\/p>\n\n\n\n
What is warehouse automation?<\/h2>\n\n\n\n\nWarehouse automation refers to using technology such as software, robotics, and equipment to execute warehouse tasks with minimal human intervention.<\/p>\n<\/div>\n\n\n\n
For example, instead of manually sorting orders<\/a> into shipping lanes, an automated sortation system can direct each box to the right dock automatically.<\/p>\n\n\n\nIt’s helpful to distinguish between mechanization (using powered tools like forklifts), digitization<\/a> (software and data for tracking), and true automation (systems that perform tasks end-to-end). Automation exists on a spectrum:<\/p>\n\n\n\n\n- Manual:<\/strong> All tasks performed by people<\/li>\n\n\n\n
- Assisted:<\/strong> People use tools (e.g., barcode scanners)<\/li>\n\n\n\n
- Semi-automated:<\/strong> Machines handle repetitive tasks, people manage exceptions<\/li>\n\n\n\n
- Highly automated:<\/strong> Integrated systems run most processes with oversight<\/li>\n<\/ul>\n\n\n\n
Most startup brands will start with a mostly manual approach and increase levels of automation with time and growth.<\/p>\n\n\n\nWhy you might need warehouse automation<\/h3><\/div>\nWhen your brand does grow, warehouse automation helps manage larger SKU<\/a> catalogues, promotional surges, peak season spikes, and labour shortages. Key outcomes to prioritize include:<\/p>\n\n\n\n\n- Higher throughput per hour<\/li>\n\n\n\n
- Lower cost per order<\/a><\/li>\n\n\n\n
- Improved pick accuracy<\/a><\/li>\n\n\n\n
- Better use of storage space<\/li>\n\n\n\n
- Resilience during demand peaks<\/li>\n\n\n\n
- Faster onboarding for new staff<\/li>\n<\/ul>\n\n\n\n
To avoid investing in the wrong technology, focus on 1\u20132 primary KPIs, such as pick rate or order accuracy, that address your biggest operational bottleneck.<\/p>\n<\/div><\/section>\n\n\n\n![\"Packages](\"https:\/\/www.shipbob.com\/uk\/wp-content\/uploads\/sites\/32\/2025\/09\/263b3e3bdc52e5d8a72e091b5edca196.jpg?w=845\")
Packages move quickly along conveyor belts in a warehouse in a blur.<\/figcaption><\/figure>\n\n\n\nWhat end-to-end warehouse automation flow typically looks like<\/h2>\n\n\n\n
Understanding the full warehouse process helps pinpoint where automation delivers the most value. The typical flow includes:<\/p>\n\n\n\n
\n- Receiving\/unloading<\/li>\n\n\n\n
- Putaway and replenishment<\/li>\n\n\n\n
- Storage<\/li>\n\n\n\n
- Picking<\/li>\n\n\n\n
- Packing and labelling<\/li>\n\n\n\n
- Sortation to shipping lanes<\/li>\n\n\n\n
- Shipping<\/a><\/li>\n\n\n\n
- Returns<\/li>\n\n\n\n
- Cycle counting<\/a><\/li>\n<\/ul>\n\n\n\n
At each step, “good” looks like minimal dwell time at receiving, efficient pick paths, and no congestion at pack stations. <\/p>\n\n\n\n
For example, if pickers spend too much time walking, automation can help by optimising routes or using goods-to-person systems.<\/p>\n\n\n\n
Warehouse automation technology options (and best-fit use cases)<\/h2>\n\n\n\n
Warehouse automation technology should be matched to your workflow and order profile, not just chosen for its novelty. Below are the main categories and their ideal applications.<\/p>\n\n\n\n
Movement and storage automation<\/h3>\n\n\n\n
Two common automated warehouse picking systems<\/a> handle inventory movement within the warehouse: automated mobile robots (AMRs) and automated guided vehicles (AGVs). <\/p>\n\n\n\n\n- AMRs<\/strong> navigate dynamically using sensors and maps, making them ideal for flexible layouts and evolving workflows.\u00a0<\/li>\n\n\n\n
- AGVs<\/strong> follow fixed paths (typically magnetic strips or wires) which makes them well-suited for steady, predictable routes with consistent traffic patterns.<\/li>\n<\/ul>\n\n\n\n
Another common type of inventory automation are Automated Storage and Retrieval Systems (AS\/RS), which come in several forms:<\/p>\n\n\n\n
\n- Unit-load:<\/strong> For pallets and large items<\/li>\n\n\n\n
- Mini-load:<\/strong> For totes and cases<\/li>\n\n\n\n
- Shuttle and cube systems:<\/strong> For high-density small-item storage<\/li>\n<\/ul>\n\n\n\n
Goods-to-person<\/a> (GTP) systems take a different approach by bringing items directly to pickers at stationary workstations, which eliminates travel time and boosts throughput. They work especially well for apparel accessories, beauty products, and home goods where order density is high and SKU variety is wide. <\/p>\n\n\n\nGoods-to-dock (or cross-docking) systems, on the other hand, are better suited for document-heavy or specialty workflows that require direct staging near shipping areas.<\/p>\n\n\n\n![\"\"](\"https:\/\/www.shipbob.com\/uk\/wp-content\/uploads\/sites\/32\/2026\/08\/900181e68dc20cdc384d81fd7cd71516.png?w=845\")
<\/figure>\n\n\n\nPicking and packing automation<\/h3>\n\n\n\n
Light-directed systems can help eliminate guesswork at the pick face, for example pick-to-light and put-to-light systems use lights to guide workers to the correct items or bins, speeding up picking while reducing errors. <\/p>\n\n\n\n
Voice picking and RF wearables further streamline the process, particularly for fast-moving SKUs. For repetitive tasks involving small, consistent products, robotic arms with vision systems can handle picking efficiently. <\/p>\n\n\n\n
Packing automation (including dimensioning, weighing, and ShipBob’s right-sized box selection<\/a> algorithm) ensures each order is packed in the most cost-effective box.<\/p>\n\n\n\nStation design also plays a critical role. Thoughtfully placed scan points and ergonomic workstations reduce travel time and speed up exception handling, keeping throughput steady even when issues arise.<\/p>\n\n\n\n![\"\"](\"https:\/\/www.shipbob.com\/uk\/wp-content\/uploads\/sites\/32\/2024\/03\/b58c0bf1583bcde0004f513b6364ea9c.jpg?w=845\")
A warehouse worker manages a pick-to-light system in a warehouse.<\/figcaption><\/figure>\n\n\n\nConveyance, sortation, and inbound handling<\/h3>\n\n\n\n
Conveyors and sortation systems (including belt, shoe, crossbelt, and tilt-tray configurations) automate the movement of orders to the right shipping lane, paying off when order volume is high and accuracy is critical.<\/p>\n\n\n\n
On the inbound side, telescopic conveyors and trailer unloaders accelerate receiving, while palletizing and depalletizing robots excel in steady, repeatable flows where consistency matters most.<\/p>\n\n\n\n![\"\"](\"https:\/\/www.shipbob.com\/uk\/wp-content\/uploads\/sites\/32\/2026\/08\/1ba7576fecad5a0596fccc8ece0bd9b5.jpg?w=845\")
<\/figure>\n\n\n\nInventory visibility tools<\/h3>\n\n\n\n
RFID tags, fixed readers, and drones can automate cycle counting and location verification, eliminating manual spot checks and reducing discrepancies. These result in higher inventory accuracy, which translates directly into faster picks and fewer exceptions at the pack station.<\/p>\n\n\n\n
Additionally, automating cycle counts, for example, cuts manual counting time while enabling more frequent checks, which supports better inventory health over time.<\/p>\n\n\n\n![\"A](\"https:\/\/www.shipbob.com\/uk\/wp-content\/uploads\/sites\/32\/2024\/11\/3849b36a5e8998204b022f989b852b7a.jpg?w=845\")
A warehouse worker scans the barcode on a unit of inventory.<\/figcaption><\/figure>\n\n\n\nImplement warehouse automation with a phased rollout plan<\/h2>\n\n\n\n
Rolling out warehouse automation in phases helps reduce risk and prove value before scaling. <\/p>\n\n\n\n
Start with a controlled pilot, then expand as you see results. The approach below walks through site preparation, pilot testing, system integration, and change management to help you build automation in stages while keeping teams aligned.<\/p>\n\n\n\nPhase 1: Prepare the site and baseline performance<\/h3><\/div>\nBegin by auditing your facility for power, network coverage, racking<\/a>, and safety zones. <\/p>\n\n\n\nDefine baseline KPIs\u2014such as pick rate or order accuracy\u2014using trusted measurement methods. <\/p>\n\n\n\n
Address “no-regrets” improvements first, like labelling standards and pick face setup, to set a strong foundation.<\/p>\n<\/div><\/section>\n\n\n\nPhase 2: Select solutions and run a pilot before scaling<\/h3><\/div>\nChoose automation solutions based on SKU size, order profile, seasonality, and layout needs. <\/p>\n\n\n\n
Run a pilot with clear success thresholds\u2014such as uptime, throughput gain, or error reduction.<\/p>\n\n\n\n
Plan for exception handling, focusing on issues like mis-scans or unlocated items.<\/p>\n<\/div><\/section>\n\n\n\nPhase 3: Use an integration-first blueprint to connect automation<\/h3><\/div>\nIntegrate automation using APIs, middleware, or event-based updates for real-time syncing. Prevent common failures like duplicate inventory sources or delayed confirmations by ensuring all systems communicate seamlessly.<\/p>\n\n\n\n
\nShipBob WMS<\/a> supports orchestration with an open API and integrations to major ecommerce platforms, ERPs, and order management systems. <\/p>\n<\/div>\n\n\n\n\n
Warehouse automation refers to using technology such as software, robotics, and equipment to execute warehouse tasks with minimal human intervention.<\/p>\n<\/div>\n\n\n\n
For example, instead of manually sorting orders<\/a> into shipping lanes, an automated sortation system can direct each box to the right dock automatically.<\/p>\n\n\n\n It’s helpful to distinguish between mechanization (using powered tools like forklifts), digitization<\/a> (software and data for tracking), and true automation (systems that perform tasks end-to-end). Automation exists on a spectrum:<\/p>\n\n\n\n Most startup brands will start with a mostly manual approach and increase levels of automation with time and growth.<\/p>\n\n\n\n When your brand does grow, warehouse automation helps manage larger SKU<\/a> catalogues, promotional surges, peak season spikes, and labour shortages. Key outcomes to prioritize include:<\/p>\n\n\n\n To avoid investing in the wrong technology, focus on 1\u20132 primary KPIs, such as pick rate or order accuracy, that address your biggest operational bottleneck.<\/p>\n<\/div><\/section>\n\n\n\n Understanding the full warehouse process helps pinpoint where automation delivers the most value. The typical flow includes:<\/p>\n\n\n\n At each step, “good” looks like minimal dwell time at receiving, efficient pick paths, and no congestion at pack stations. <\/p>\n\n\n\n For example, if pickers spend too much time walking, automation can help by optimising routes or using goods-to-person systems.<\/p>\n\n\n\n Warehouse automation technology should be matched to your workflow and order profile, not just chosen for its novelty. Below are the main categories and their ideal applications.<\/p>\n\n\n\n Two common automated warehouse picking systems<\/a> handle inventory movement within the warehouse: automated mobile robots (AMRs) and automated guided vehicles (AGVs). <\/p>\n\n\n\n Another common type of inventory automation are Automated Storage and Retrieval Systems (AS\/RS), which come in several forms:<\/p>\n\n\n\n Goods-to-person<\/a> (GTP) systems take a different approach by bringing items directly to pickers at stationary workstations, which eliminates travel time and boosts throughput. They work especially well for apparel accessories, beauty products, and home goods where order density is high and SKU variety is wide. <\/p>\n\n\n\n Goods-to-dock (or cross-docking) systems, on the other hand, are better suited for document-heavy or specialty workflows that require direct staging near shipping areas.<\/p>\n\n\n\n Light-directed systems can help eliminate guesswork at the pick face, for example pick-to-light and put-to-light systems use lights to guide workers to the correct items or bins, speeding up picking while reducing errors. <\/p>\n\n\n\n Voice picking and RF wearables further streamline the process, particularly for fast-moving SKUs. For repetitive tasks involving small, consistent products, robotic arms with vision systems can handle picking efficiently. <\/p>\n\n\n\n Packing automation (including dimensioning, weighing, and ShipBob’s right-sized box selection<\/a> algorithm) ensures each order is packed in the most cost-effective box.<\/p>\n\n\n\n Station design also plays a critical role. Thoughtfully placed scan points and ergonomic workstations reduce travel time and speed up exception handling, keeping throughput steady even when issues arise.<\/p>\n\n\n\n Conveyors and sortation systems (including belt, shoe, crossbelt, and tilt-tray configurations) automate the movement of orders to the right shipping lane, paying off when order volume is high and accuracy is critical.<\/p>\n\n\n\n On the inbound side, telescopic conveyors and trailer unloaders accelerate receiving, while palletizing and depalletizing robots excel in steady, repeatable flows where consistency matters most.<\/p>\n\n\n\n RFID tags, fixed readers, and drones can automate cycle counting and location verification, eliminating manual spot checks and reducing discrepancies. These result in higher inventory accuracy, which translates directly into faster picks and fewer exceptions at the pack station.<\/p>\n\n\n\n Additionally, automating cycle counts, for example, cuts manual counting time while enabling more frequent checks, which supports better inventory health over time.<\/p>\n\n\n\n Rolling out warehouse automation in phases helps reduce risk and prove value before scaling. <\/p>\n\n\n\n Start with a controlled pilot, then expand as you see results. The approach below walks through site preparation, pilot testing, system integration, and change management to help you build automation in stages while keeping teams aligned.<\/p>\n\n\n\n Begin by auditing your facility for power, network coverage, racking<\/a>, and safety zones. <\/p>\n\n\n\n Define baseline KPIs\u2014such as pick rate or order accuracy\u2014using trusted measurement methods. <\/p>\n\n\n\n Address “no-regrets” improvements first, like labelling standards and pick face setup, to set a strong foundation.<\/p>\n<\/div><\/section>\n\n\n\n Choose automation solutions based on SKU size, order profile, seasonality, and layout needs. <\/p>\n\n\n\n Run a pilot with clear success thresholds\u2014such as uptime, throughput gain, or error reduction.<\/p>\n\n\n\n Plan for exception handling, focusing on issues like mis-scans or unlocated items.<\/p>\n<\/div><\/section>\n\n\n\n Integrate automation using APIs, middleware, or event-based updates for real-time syncing. Prevent common failures like duplicate inventory sources or delayed confirmations by ensuring all systems communicate seamlessly.<\/p>\n\n\n\n ShipBob WMS<\/a> supports orchestration with an open API and integrations to major ecommerce platforms, ERPs, and order management systems. <\/p>\n<\/div>\n\n\n\n\n
Why you might need warehouse automation<\/h3><\/div>
\n
What end-to-end warehouse automation flow typically looks like<\/h2>\n\n\n\n
\n
Warehouse automation technology options (and best-fit use cases)<\/h2>\n\n\n\n
Movement and storage automation<\/h3>\n\n\n\n
\n
\n
<\/figure>\n\n\n\nPicking and packing automation<\/h3>\n\n\n\n
Conveyance, sortation, and inbound handling<\/h3>\n\n\n\n
<\/figure>\n\n\n\nInventory visibility tools<\/h3>\n\n\n\n
Implement warehouse automation with a phased rollout plan<\/h2>\n\n\n\n
Phase 1: Prepare the site and baseline performance<\/h3><\/div>
Phase 2: Select solutions and run a pilot before scaling<\/h3><\/div>
Phase 3: Use an integration-first blueprint to connect automation<\/h3><\/div>
![\"\"](\"https:\/\/www.shipbob.com\/uk\/wp-content\/uploads\/sites\/32\/2026\/08\/c19bc137ff11fd5ee30c82ccd7bf47d6.png?w=845\")
<\/figure>\n\n\n\n![](\"\/wp-content\/themes\/shipbob-2022\/resources\/svg\/plus-solid.svg\"\/)
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