Finding the right balance between manual and automated handling solutions

There is an evolving debate between manual and automated material handling solutions in manufacturing and warehousing.

Diana Davoyan, who writes about warehouse robotics, recommends a balanced approach. Depending on the warehouse type, some will keep to a mainly manual approach, but many will mix autonomous tools with human-operated equipment,

Each approach has distinct advantages: Manual handling offers more opportunity for human intuition and flexibility for handling unexpected situations and irregular tasks, while automated systems excel at repetitive, high-volume workflows requiring consistency and precision.

Newly-built facilities can integrate automation from the start, while existing sites often require gradual implementation due to infrastructure constraints.

Hybrid solutions are common, with many organisations finding it better to combine both approaches, using worker-driven forklifts and aisle picking trolleys for judgment-heavy tasks and robots for routine, predictable ones.

Diana Davoyan says that companies should optimise existing processes before considering automation. Use intelligent software to improve current material handling systems effectively. What matters is not the type of handling equipment used, but whether it is used intelligently and is the best fit for the task.

Before introducing automation, its downsides need to be considered. Automated tools are prone to breakdowns, which cause downtime. There are safety risks if robots are working in the same area as human workers. Error rates can be high until automated machinery is fine-tuned.

A warehouse or manufacturing facility’s success comes from aligning handling technology with workers to fit each operation’s unique needs, rather than simply favouring an automated or manual-based solution.

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