Finding the Right Robot
5 Things That Will Make or Break Your Investment
By Ben Gruettner & Kyle Detwiler
Some facilities achieve transformational ROI. Others struggle to realize the value they expected. The difference rarely comes down to the robot itself. Success depends on whether organizations evaluate the right inputs before deployment.
We’ve found that there are five factors that consistently determine whether a robotics investment delivers meaningful impact — or simply shifts operational complexity elsewhere.
1. Understand Where Pickers Spend Their Time
Before introducing automation, organizations must first understand how their work is currently being performed. The goal is not to automate existing inefficiencies — it is to eliminate them.
That requires visibility into:
Travel patterns
Idle time
Task switching
Congestion points
Non-value-added activities
Without this baseline, it is impossible to determine where robotics can create measurable improvement or how the solution will affect workflows. Mapping picker activity provides the foundation for identifying ROI opportunities.
2. Define the Problem You’re Actually Solving
Robotics is not a one-size-fits-all solution. Different systems excel at solving different operational challenges.
For example, organizations may prioritize:
Reduced travel distance
Lower dwell time
Higher throughput
Improved labor flexibility
Better space utilization
Not every robotic solution can significantly influence each of these variables equally. Selecting the right technology therefore begins with clearly defining the operational objective. When companies fail to align technology with the problem being solved, expectations quickly become unrealistic.
3. Evaluate How Robot-Friendly Your Environment Is
Warehouse environments vary dramatically in complexity. Layout, SKU variability, dynamic obstacles, human interaction, and process variability all influence robotic performance.
Equally important, robots interpret the world differently:
Some rely heavily on structured environments, predictable flows
Others leverage perception and autonomy to navigate complexity
Understanding how a robot perceives and responds to its surroundings is essential. A solution that performs well in a controlled demonstration environment may struggle in a dynamic production facility if environmental complexity exceeds its capabilities.
Successful deployments occur when technology and environment match, even as each one evolves.
4. Move Beyond Paper-Based Calculations
Static spreadsheets and high-level estimates are no longer sufficient for evaluating robotic deployments. Be cautious of vendor claims that lack evidence or operational modeling. Performance metrics such as throughput gains and labor savings must be grounded in realistic analysis.
Simulation has become a critical evaluation tool because it:
Models real workflows
Identifies bottlenecks before deployment
Stress tests assumptions
Predicts utilization and ROI more accurately
Simulation is not just helpful — it determines whether an investment succeeds or fails.
5. Consider the Entire Supporting Workflow
Labor savings are often a central justification for robotics, but focusing solely on picker reduction can obscure downstream impacts.
Automation may reduce headcount in one area while increasing labor requirements elsewhere, such as:
Loading and unloading robots
Staging and replenishment
Exception handling
Traffic coordination
Maintenance support
If supporting workflows are not accounted for, organizations risk shifting complexity rather than eliminating it. A holistic view of the operation ensures that robotics truly improves productivity instead of redistributing inefficiencies.
The Right Robot Context
Selecting the right robot is less about comparing feature lists and more about understanding operational context.
Successful deployments occur when organizations:
Analyze current workflows with precision
Define clear objectives
Align technology capabilities with environmental complexity
Use simulation and data-driven evaluation
Account for the full operational ecosystem
When these factors are addressed early, robotics investments are far more likely to deliver sustained value. For organizations exploring warehouse automation, the challenge is rarely a lack of available technology. The challenge is identifying which solution best fits the realities of a specific operation.
If you’re evaluating robotics and struggling to determine the right path forward, the answer often begins with a deeper understanding of your workflows, environment, and objectives. Finding the right robot is not about automation in isolation. It’s about truly knowing your operation.
