As warehouses increasingly turn to automation to meet growing supply chain demands, organisations need to understand that no two facilities are identical. While automation promises operational benefits, successful implementation requires careful consideration of critical factors that can make or break your project.

Floor Quality: The Foundation of Success

The foundation of any automated warehouse system – quite literally – is the floor. A high-quality floor isn’t just about being smooth; it requires specific characteristics to support automated systems effectively:

• Both flatness and levelness, especially for high-reach mobile robotics requiring F/min 60 range specifications
• Surface finish must balance dust prevention with adequate grip for robot wheels
• Construction joints require special attention, with most mobile robots accepting gaps up to 7mm
• Regular cleaning and maintenance as dirty floors can interfere with navigational markers
• Angular rotation of floor slabs is another element to consider if looking at shuttle system
• As with ASRS angular rotation is also a big factor plus point load and slab thickness

Building Height Considerations

While some automated systems, such as autonomous carton robots, operate comfortably at standard heights of 4.2 to 5.4 meters, others like high ACR’s, Turret Trucks and Shuttle systems can reach up to 12 metres. This increased height brings additional considerations:

• Higher reaches demand superior floor quality due to inertial forces
• Taller installations may require multiple levels of in-rack sprinklers
• Balancing fire safety requirements with storage capacity optimisation

Environmental Control

The quality of air can make a big difference to the performance of different automation:

• Temperature tolerance typically ranges from +5°C to 45-50°C
• Ventilation must be managed carefully to prevent debris accumulation
• Open doors can introduce dust and debris that impact system performance
• Areas shared with traditional forklifts require extra vigilance against dropped materials that could obstruct automated vehicles

Network Infrastructure

Reliable wireless connectivity is fundamental:

• Each system requires a dedicated Wi-Fi backbone on secure channels
• Signal gain consistency – fluctuations can severely impact robot performance
• Meeting or exceeding vendor-specified network requirements
• Signal loss during tasks can create significant operational challenges

Maintenance Access and Safety

Perhaps the most critical consideration is ensuring safe access for maintenance:

• All automated systems require regular maintenance, regardless of manufacturer
• Access requirements vary significantly between low-rise AMRs, high-reach ACRs and shuttle systems
• Proper safety equipment for maintenance, such as scissor lifts for high-reach systems
• Clear safety protocols and restricted access procedures
• Training and awareness are crucial to prevent accidents, especially in facilities with mixed operations

As automation technology continues to evolve, fundamental installation principles can’t get left behind. While the allure of automation is strong, success lies not just in the technology itself, but in how well it’s matched to your facility’s specific characteristics and capabilities. No two warehouses are the same, and realising this can be the difference between a transformative success and a costly learning experience.