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How to Modernize Your Warehouse Without Starting Over
Q If I want to improve my warehouse performance, do I really need a brand- new facility or a full retrofit? A Not at all. That’s one of the biggest misconceptions out there. Companies often think they need to spend heavily on a new facility to upgrade with automation or increase capacity—but that’s usually because they’re thinking of older, fixed-infrastructure solutions that require extensive preparation and long downtime. Modern automation systems are much more adaptable. For example, modular Automated Storage and Retrieval Systems (ASRS) like HaiPick can operate in existing facilities with minimal floor prep. These systems leverage vertical space—up to 39 feet high—to condense inventory and store more in less space. We’ve seen customers reduce their storage footprint by up to 75% while increasing capacity by as much as 4x. The key is to look for modular, flexible automation that integrates with your current layout and can scale easily over time. HaiPick Systems, for example, use a catalog of modular components—including industry-standard racking and a wide range of container types and sizes—tailored to fit your operation. That modularity makes it easier to implement around ongoing operations, expand or adjust after deployment, and break up capital investments to align with your business growth.
Q What’s a simple way to start automating without taking on huge risk or cost? A Start small, stay flexible, and scale up when it makes sense. You don’t have to go all-in on day one. A modular approach lets you optimize a single zone, workflow, or picking process first, then expand as needed. ASRS solutions like HaiPick are a great entry point because they tackle one of the most labor-intensive and error-prone parts of warehousing: inventory handling and order picking. Instead of walking 10-15 miles each shift, workers stay at ergonomic, easy-to-use picking stations while mobile robots retrieve and deliver totes, trays, cases, or even pallets of goods. This speeds up fulfillment and boosts accuracy to over 99%. Q How does this kind of automation actually impact day-to-day operations— and the bottom line? A With robots handling the travel, workers can fulfill up to 30 orders at once from a single workstation—significantly boosting daily throughput, accuracy, safety, and overall efficiency. This enables later order cutoff times, expanded SLAs, and helps reduce workplace injuries, turnover, and training time. Most importantly, flexible goods-to-person systems like HaiPick deliver fast ROI in your existing facility: up to 4x increased efficiency, 3x more throughput, 75% reduced storage footprint, and 67% reduced labor costs—all while staying nimble for future growth.
Hunter Senn Vice President of Sales Hai Robotics USA hunter.senn@hairobotics.com www.HaiRobotics.com
May 2025 • Inbound Logistics 25
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