Hybrid Automation Blends Technology and Human Labor for Optimal Efficiency

The human warehouse worker is still vital to the success of operations even as automated solutions continue to grow, according to a new study from Newcastle Systems.

“Although robotics and automation are becoming more relevant in warehouses across the globe, workers are still essential resources in these workplaces,” write the authors of the study.
“Automation assists human workers to become more productive and efficient.”

While the benefits of automation have been transformative for the modern warehouse, the report notes that humans are still necessary to oversee equipment and work collaboratively with the technology for optimal results.

The study finds that striking the right balance between machine and man is critical in achieving the greatest efficiency in your operations. This hybrid approach to automation is already popular amongst those surveyed by Newcastle, with 50% of companies running fulfillment operations that include a combination of automated and manual processes. Another 46% said that most or all fulfillment processes are completely manual, and only 2% said they have “highly automated” fulfillment operations.

What is a hybrid warehouse?

According to the report, a hybrid warehouse combines the advantages of automation and human labor by leveraging technology and skilled workers to optimize operations, with the goal of increased efficiency, reduced operational costs, and improved customer satisfaction. Hybrid warehouses are made up of several key elements, including flexibility and scalability, efficient automation integration, a skilled workforce, and the ability to adapt to changing technology.

The report also identified several technologies that can help companies achieve hybrid automation, including mobile workstations, wearable devices, exoskeleton tools, and collaborate robots (cobots).

Mobile workstations essentially cut the cord, allowing workers to bring their workstation with them instead of being tethered to one location.

Wearable devices, such as barcode scanners or smart glasses, not only boost efficiency but offer more ergonomic solutions to keep workers safer and more comfortable.

Exoskeleton tools are similar to wearable devices in that they provide ergonomic support for heaving lifting. Exoskeletons are typically lightweight, external frames, backpacks or vests a worker wears to support and enhance performance and help prevent common back, knee or shoulder injuries.

When you think hybrid automation, cobots might be the first technology that comes to mind. These robots work side-by-side with humans. They are growing in popularity in the material handling industry by taking on more physically demanding tasks such as picking, packaging, and palletizing.

“Modern warehouses need to stay updated on the latest technology to optimize efficiency and match the recent innovative trend of the industry,” write the authors of the report. “Without it, the full potential for maximized time and throughput will not be achieved, thus, less revenue growth.”