The Material Handling Blog

Automation is not all or nothing. Many businesses start small, expand over time, or implement larger systems when the volume and complexity of their operations require it. The key is to choose the level of automation that aligns with your goals, growth plans and available resources. Automation technologies are used to automate tasks such as inventory management, order fulfillment and material handling, reducing manual intervention and errors.

A few years ago, a Midwest warehouse faced familiar pressures: limited space, rising labor costs, and growing demand for faster fulfillment. Rather than building new, they retrofitted their existing distribution center. By upgrading within their current footprint, they streamlined operations and gained flexibility without disrupting business. Across warehouse, distribution, and manufacturing environments, companies are rethinking their approach to modernization. Brownfield projects—automation retrofits within existing facilities—are gaining traction as a practical, lower-risk alternative to greenfield construction. Whether due to tighter budgets, uncertain economic conditions, or a desire to move quickly without adding square footage, leaders are seeking ways to do more with what they already own. In many cases, they’re finding that a smart retrofit delivers the operational improvements they need, without the time or capital required to start from scratch.

Ever tried cramming one last outfit into an already overstuffed suitcase? You push, you fold, you sit on top of it—and still, the zipper won’t budge. That’s exactly how many distribution centers feel when they hit capacity. There’s always one more pallet, one more SKU, one more shipment to squeeze in, but eventually, you run out of room. Unlike a suitcase, warehouses can’t just swap to a bigger model at the last minute. Space constraints in distribution centers lead to far more than just a tight fit—they create bottlenecks that slow operations, increase costs, and make it harder to meet customer expectations. Running out of space isn’t just an inconvenience for companies looking to scale - it’s a roadblock to growth. The good news? With the right material handling automation strategy, you can optimize the space you already have.

Labor and resource planning has always been a moving target. Even the most well-run warehouse or fulfillment center can struggle to match staffing levels with demand. When the right people aren’t available at the right time, delays stack up, costs rise, and service levels slip. Operations teams are up against a familiar set of challenges like fluctuating order volumes, high turnover, and inefficient workflows that create bottlenecks. In the 2024 MHI Annual Industry Report, more than half of material handling leaders cite talent shortages—hiring and retaining qualified workers—as one of their biggest challenges, ranking it as very or extremely difficult to manage. Scaling up often means adding temporary workers or increasing overtime, but that’s not a sustainable strategy. How work is structured and allocated has just as much impact on efficiency as the number of workers on the floor. Material handling automation provides a way to stabilize operations, improve labor efficiency, and optimize resources without relying on constant hiring cycles. But before looking at the solutions, it’s important to understand where the biggest inefficiencies emerge and why workforce planning remains a challenge.

The integration of emulation software and PLC represents a ground-breaking advancement in industrial automation. By leveraging emulation software, we can construct a virtual model of physical systems, allowing for real-time testing and validation. When synchronized with PLCs, the digital twin accurately replicates the behaviour of the physical system, offering valuable insights into performance, troubleshooting and optimization.

Automation in material handling is often celebrated for its ability to increase speed, accuracy and efficiency while reducing operational costs. However, one crucial factor determining the success of automation projects is often overlooked: employee adoption. Implementing new systems isn't just about integrating technology; it's about ensuring the people impacted by these changes understand, accept and embrace them. When executed well, change management bridges this gap, driving both operational success and a positive work culture.

“Let’s look at this thing from a standpoint of status. What do we got on the spacecraft that’s good? “ –Gene Kranz (Ed Harris), “Apollo 13.” There’s a lot of genius in that simple question. If you haven’t watched the movie, it’s worth a few hours of your time. The quick summary is that the mission was in serious trouble, Gene Kranz had just put on the flight director vest, and he was beginning the process of recovering not just the equipment, but most importantly, the crew of the Apollo 13 spacecraft. The genius in the question is recognizing that you have no ability to reach an endpoint if you don’t know where you are at the beginning.

As a leading systems integrator, Bastian Solutions understands material handling solutions do not come in a one-size-fits-all package. The company holds decades of experience across a broad spectrum of industry verticals and our experts partner with customers to engineer warehouse automation and material handling systems designed to achieve business objectives. Bastian is eager to exhibit at MHI’s MODEX 2024 trade show March 11-14 in Atlanta, Georgia. Booth B5619 will feature various automation and technology, along with opportunities to learn more about how Bastian can help select, implement and optimize the right material handling equipment and processes to Engineer Your Competitive Edge!