Warehouse Workers and Robots: Tackling 3 Key Concerns

By Brandon Marsico, Lucas Systems

As I explored in my recent blog post about the prospect of robots replacing humans in warehouse work, the integration of robots into warehouses and distribution centers is transforming the way that goods are stored, retrieved, and shipped. But as warehouse workers become more accustomed to working alongside robots, they may still have some fears about how automation will impact their job security.

What scares warehouse workers about robots?

Job loss – It should come as no surprise that job loss is a common fear when talking about implementing robotics and automation. According to this article by the World Economic Forum, almost a 5th of US workers claim they fear AI and have “FOBO” or Fear of Becoming Obsolete.

Automated systems can reduce the need for human labor by completing certain menial tasks faster and with fewer errors than humans could do on their own. This raises questions about job security for those who work in warehouses and distribution centers – especially as companies continue to invest in automation technology over traditional manual labor. In fact, we are hearing more and more about warehouse leaders not necessarily using automation tech to replace workers, but to help close the gaps in hard to fill positions on the warehouse floor.

Interestingly, according to our Voice of the Warehouse Worker case study, 73% of Gen-Z warehouse workers believe robots could be beneficial partners to help them perform their jobs more efficiently and reduce physical stress, but overall concerns about job loss, safety, lack of control, and higher quotas still pose potential barriers. To address this, gradually integrate robots into the worker environment through pilot programs that pair robots with employees. Demonstrating success in areas that reduce physical strain and travel time for workers can help build trust and reassure them that robots can have a positive impact on their roles.

Lucas Systems’ partner Zebra Technologies deployed autonomous mobile robots to help cultivate produce for customer Hippo Harvest. The Zebra system allowed the AMRs to work for up to 20 hours a day, keeping the farm operating efficiently even in a time of labor scarcity. The Hippo Harvest CEO said, “The robots do a lot of these repetitive and ergonomically challenging tasks that people don’t want to do in today’s environment.”

Job Safety – Another common fear among warehouse workers is safety when working with robots daily. Automated systems can be extremely powerful machines capable of moving heavy loads quickly without taking breaks like humans do—but this also means there’s an increased risk of accidents if proper safety protocols aren’t always followed closely while operating robotic machinery or performing maintenance activities around them. Additionally, if not programmed properly, a robot could malfunction unexpectedly leading to potential injury or damage to property within the facility due to negligence or incorrect programming instructions given by operators/programmers unfamiliar with robotics technology used in such settings.

Because warehouse work typically involves repetitive motions such as lifting, carrying, and walking over long periods of time, offloading tasks requiring these movements to a machine can reduce the number of workplace accidents and physical injuries. Furthermore, cobots (collaborative robots designed specifically to work alongside humans) are equipped with a breadth of technology including advanced sensors and algorithms designed to avoid human collisions in the workplace. According to ISA (International Society for Automation), cobots can reduce 3 out of the top 5 most common workplace injuries such as, eliminating contact with harmful objects, heavy lifting, and repetitive stress injuries ultimately reducing workplace injuries by up to 72 percent. The U.S. Bureau of Labor Statistics found automation significantly decreases the risks associated with forklift-related accidents, which account for nearly 10% of all workplace injuries in warehouses, by reducing the need for manual transportation. Furthermore, autonomous mobile robots (AMRs) equipped with sensors and AI have a near-zero collision rate in warehouses, as they predict and avoid obstacles, reducing accidents caused by human error or equipment mismanagement. The result? Humans and machines working together in harmony with minimal risk to the worker.

Zebra customer Austin Lighthouse integrated four AMRs into their facility to transport empty carts from one location to another as well as for case picking. The AMRs made it easier for its 450 workers (250 of them are legally blind) to handle orders and considerably reduced their travel time. Their Vice President of Business Innovation said, “We were drawn to robotics as a way to enable all of our employees to work smarter, not harder. Reducing the amount of walking they must do to complete a task, in turn, reduces wear and tear on the body and opens up job opportunities to those with limited mobility.”

Loss of control – According to our Voice of the Warehouse Worker case study, 31% of respondents to our survey said they feared robots would impede them from doing their job because they wouldn’t be able to control the robot.

This can mean a number of things. It could be because of lack of familiarity with technology. Many workers may feel intimidated by robots, especially if they aren’t familiar with the technology. They might worry that their lack of technical knowledge or training will prevent them from operating or controlling the robots effectively. Robots, especially autonomous ones, can seem complex, with various programming and operating systems. Workers may fear they won’t be able to intervene or adjust the robot’s actions if something goes wrong, leading to a sense of helplessness. This sentiment also feeds into a lack of training and familiarity with new technology. It’s up to the employer to ensure employees are confident and comfortable in working closely with the technology, what this division of labor is, and what to do in case of malfunction.

With the proper understanding, training and labor delineation, the uses of robots can actually enhance satisfaction and engagement. Referencing our earlier example with Zebra Robotics, according to Hippo Harvest’s CEO, “We employ robots to allow human operators to do more with less and to focus on the jobs that they are excited about that use their skills to their full potential.”

Minimize fears with a worker-focused collaborative plan

Incorporating automation into your warehouse or distribution center can reap significant benefits for your business, but it’s crucial to openly acknowledge the concerns of your workforce and take action to alleviate those concerns to ensure a smooth transition. By understanding and alleviating fears related to job security, safety, and control, you can foster a more positive and productive work environment.

Speak with your staff about the changes and involve them in the integration process. Utilize pilot programs that pair robots with workers to build trust and demonstrate the advantages of automation. Think things like full pallet moves and transfers. Robots perform full-pallet put-away or replenishment moves, replacing people in one of the most travel-intensive activities in the DC. When a worker requests a replenishment, robots answer the call.  Lastly, highlighting success stories, like those from Austin Lighthouse and Hippo Harvest, can also help illustrate the potential for robots to enhance, rather than replace, human roles.

Ultimately, a thoughtful and collaborative approach to robotics can lead to a more efficient, safe, and satisfying workplace for everyone. By prioritizing the well-being and concerns of your employees, you can harness the full potential of automation technology while maintaining a motivated and engaged workforce.

Brandon Marsico is a dynamic and analytical professional with a diverse background, encompassing nearly a decade of experience in strategic digital marketing and project management across various industries. A U.S. Army combat veteran, Brandon has transitioned his leadership skills and disciplined approach to the civilian sector, currently specializing in supply chain and distribution.

Throughout his career, Brandon has established himself as a natural leader with a proven track record of dramatically driving revenue, expanding market presence, and enhancing online visibility and positioning. His expertise lies in leveraging data-driven insights to build high-performance teams and design custom, scalable SEO strategies and digital campaigns that align with clients’ and organizations’ visions, missions, and long-term business objectives.