How automation is reducing fulfilment times

Leading retailers and wholesalers use robotics, AI, and digital systems to process more orders, with fewer mistakes, at a lower cost.

The rush for faster fulfilment

Warehouses have changed a lot in the past few years. Online shopping keeps growing and people want their orders to arrive quickly. People remember bad experiences and inform others of that experience.

Fast fulfilment means fewer missed sales and fewer unhappy customers.

However, many warehouses still use legacy processes that slow everything down. It can increase mistakes and cost more money.

Retailers and logistics companies feel pressure from every side.

• Labour shortages make it hard to find enough staff.
• Costs keep going up.
• Customers expect same-day or next-day delivery.

Businesses need a way to stay competitive and keep up with demand. Automation offers a way forward.

Robots and smart systems are handling more of the heavy work. They help warehouses get orders out the door faster and more accurately to reduce human error.

This is a necessity for businesses wanting to meet expectations and save money at the same time.

How warehouse automation is growing

The use of automation in warehouses has grown fast. A decade ago, only a few large companies used robots or smart tech.

Now things are changing. Many businesses are seeing that AI solutions save retailers time and money.

In 2024, one in four warehouses uses some form of automation. That number keeps on rising.

Over half of warehouses are planning to spend more on automation soon. The warehouse automation market is worth billions and continues to expand.

Speed is one reason for this change. Labour shortages are another. Manual processes cannot keep up with the pace of online retail. Automated systems do not get tired and work around the clock.

Fewer mistakes happen because robots and software follow instructions every time. These systems also help minimise costs by using fewer resources to do the same job.

Adopting AI solutions is easier than a lot of people think.

Warehouse automation results in businesses across the world

Warehouse automation is not just theory.

Businesses of all sizes now use smart systems and robots. They do this to speed up fulfilment, reduce errors, and keep customers happy.

The following examples show what is possible with automation in real businesses.

Warehouse automation examples from the UK and Europe

THG Fulfil is an ecommerce provider based in the UK.

In 2023, they installed fleets of small robots from a company called Geekplus.

• Over four million standard orders moved to next-day delivery at no extra cost to the customer.
• Delivery time fell to about a day and a half, far below the usual three to five days seen in the industry.
• Customer retention rose because orders turned up faster and more reliably.

In 2024, Geekplus also sent a fleet of Goods-to-Person robots to THG Fulfil for its Omega facility. This allowed THG to increase warehouse performance by supporting palletised items of all sizes.

John Lewis uses 60 autonomous robots at its Milton Keynes distribution centre.

• This raised storage space by three quarters and saved one million pounds each year.
• The robots also meant less manual handling of stock and sped up order processing. It proved to be vital during busy periods like Christmas.
• Fewer errors happen and stock moves more smoothly through the system.

Ocado runs some of the most advanced grocery warehouses in the world. They use robotic arms and machine learning to pick and pack food orders.

• Hundreds of orders get processed at the same time, often within minutes.
• Robots work through the night and weekends, so there are no slow periods.
• Workers no longer need to walk long distances or search for products.
• The robots bring everything straight to them, which makes every step faster.

More European companies are moving robots into the supply chain and warehouse.

• GXO Logistics now uses camera systems with artificial intelligence to check and pick orders.
• Superdry, a clothing retailer, brought in forty-six robots to improve returns processing and speed up fulfilment.
• IKEA uses automated mini-warehouses where robots handle stock almost entirely on their own.

Warehouse automation studies from the United States

American companies also see the value in automation.

Amazon has more than 750,000 robots across its fulfilment network. In 2023, a new centre in Louisiana used a system called Sequoia.

This uses mobile robots, cameras, and smart software to sort and store inventory up to 75% faster than before.

• Items move directly to pickers.
• Orders spend less time waiting and more time on their way to customers.

As a result, Amazon increased same-day deliveries by nearly two thirds in just one year. Last year, over five billion packages went out with same-day or next-day speed.

Amazon uses data to keep products closer to customers. Robots help sort, pack, and move items quickly. This makes their system much more efficient than manual warehouses.

UPS and DHL are also making changes.

• UPS uses smart route planning to save time on deliveries. Its system checks thousands of possible routes in seconds. This cuts delivery times and saves fuel.
• DHL uses robots for sorting and picking in many warehouses around the world. Automation has cut their operating costs in the UK and improved planning for busy periods. Their delivery times also fell.

Warehouse automation and fulfilment trends in Asia

Asia has some of the fastest warehouses in the world.

Alibaba Cainiao operates a network aimed at delivering most domestic orders in China within twenty-four hours. To do this, they use robots called Quicktron that bring shelves to workers.

• This cuts walking distance by up to 90% and lets people pick more items in less time.
• It achieved an overall accuracy of 99% in sortation and parcel handling
• Workers can now handle up to 200,000 order lines per day, about three times more than before.
• In some centres, international parcels arrive in less than three days. In a new Middle East centre, last-mile delivery times dropped by about a quarter.

Retailers across South Korea, Japan, and Singapore have invested in automated shuttle systems and pick-to-light technology.

These systems keep warehouses running twenty-four hours a day. Orders that used to take a day now go out in a few hours. They reduce picking times, meaning more orders, less waiting, and fewer errors.

How warehouse automation works

Modern warehouse automation uses a mix of robots, software, and smart machines.

• Goods-to-person systems bring items straight to a worker’s station, saving time and effort. Robotic arms do the picking and packing.
• Smart conveyor belts and autonomous vehicles move goods around without needing a person to push or drive them.
• AI-powered vision systems check products for mistakes and pick out damaged goods. This means less time checking and rechecking orders.

Systems like GXO’s Operator Eye use cameras and smart software to spot problems early. It stops errors before they reach the customer.

Do robots replace warehouse staff?

Robots do not replace people. They work with them. Workers spend more time on skilled jobs. Robots take care of the boring, heavy, or repetitive tasks.

This keeps staff safer and happier. AI and automation lets people focus on jobs that need judgement and problem solving.

How to automated robots fit in fulfilment warehouses?

Warehouse layouts also change. Racks and shelves get built for robots to move through easily. The design is not about making people walk as little as possible. Instead, robots and conveyors handle the travel.

A change in layout unlocks even more speed and efficiency.

Some companies are now building new digital platforms to support automation across their fulfilment operations.

The benefits of warehouse automation

Faster fulfilment is the main benefit.

Orders get picked and shipped much sooner. Customers notice when their orders arrive quickly and without mistakes. Fewer orders go missing and returns become easier to handle.

These systems help businesses optimise warehouse or fulfilment tech stacks for future growth.

Operating costs come down 📉

Fewer mistakes mean less wasted time and stock. Companies can manage busy seasons without needing as many extra staff.

• This makes costs more predictable.
• Less time searching for lost products or fixing errors.
• Robots keep working during the night, on weekends, and on holidays.

Improved accuracy 🎯

Machines follow instructions the same way every time.

• This leads to fewer wrong items in boxes.
• Less money spent on fixing errors.
• Fewer returns happen because customers get what they actually ordered.
• Accurate and speedy orders will result in positive customer experiences.

Health and safety benefits 👷‍♀️

Robots handle lifting and moving heavy items.

• This lowers the risk of injuries.
• Staff can focus on jobs that do not put them at risk.
• Automation helps workers become healthier and more engaged.

Scalability becomes much easier 📈

If a business needs to process more orders, robots and systems can handle extra demand without slowing down.

Companies can grow without needing to find lots of new staff each time. Automated solutions working with staff will improve productivity and increase efficiency.

How warehouse automation is shaping the future of order fulfilment

Warehouse automation solutions aren't just for the biggest companies.

More businesses are investing because they cannot afford to fall behind.

Businesses that automate now put themselves in a strong position to keep up with customer expectations.

• They cut costs and improve reliability.
• Their staff can do better work.
• Customers trust them to deliver.

The gap between manual and smart warehouses will only get wider.

Manual processes can only take you so far. Automation reveals new ways to meet demand and keep customers happy.

Warehouses that move to automated systems get faster, more reliable, and ready for the future. Now is the time to think about what automation can do for your business.

Each step towards automation brings gains in speed, cost, and customer satisfaction.

Companies that make the move see the benefits every day in their fulfilment times and their bottom line.