Automation brings speed, efficiency, and precision to the working world. In busy, complex environments, like a warehouse or distribution center, these benefits are invaluable. So, more and more warehouses across the globe are embracing automated warehouse control systems in various forms to expedite warehouse operations.

This guide examines those systems, exploring their functions, features, and differences. It also takes a look at the many benefits of automated equipment in the warehouse and explores future trends for businesses to keep an eye on.

Key Takeaways

• Automated warehouse control systems streamline material handling and improve efficiency through technologies like WMS, WCS, and robotics.
• Emerging trends like AI, IoT, and predictive analytics are transforming how warehouses operate and scale.
• Integrated control systems (like Logix WCS by BoxLogix) can enhance real-time visibility, optimize order flow, and support scalable automation across warehouse operations.

Introduction to Automated Warehouse Control Systems

So, what do we mean when we talk about an automated warehouse control system, or warehouse automation in general? In a nutshell, it’s all about using automated systems and software to take over many of the essential tasks needed to keep warehouses running smoothly, controlling the flow of products, materials, equipment, and personnel.

Automation systems ease the burden on human warehouse workers while streamlining numerous warehouse processes. At a time when supply chains are moving more rapidly than ever, and consumer expectations around speed and efficiency have reached unprecedented levels, this technology is no longer an optional extra or helpful bonus. It’s a must-have.

Core Components of Automated Control Systems

There are three core components of automated warehouse technology:

• Warehouse Management System (WMS): This is responsible for managing crucial warehouse and supply chain operations, i.e., reception of goods, picking, shipping, and inventory replenishment.
• Warehouse Execution System (WES): This controls the physical movement of materials through the warehouse, plotting the routes that goods will take and ensuring that the correct instructions are sent out to equipment and warehouse employees.
• Warehouse Control System (WCS): This directly controls the physical actions of material handling equipment throughout the distribution center, i.e., conveyors, robots, sorters, and so on.

Types of Automated Warehouse Control Systems

In addition to the three core components listed above, we can also divide warehouse automation technologies into multiple additional groups and forms. These include:

• Automated Storage and Retrieval Systems: Just as the name implies, these are used for both storing and retrieving goods from specific locations around the warehouse, with the aid of automated equipment, such as cranes and robotics.
• Conveyors: Integral pieces of equipment in automated warehouses, conveyors transport goods from place to place within the facility. They come in different forms, like rollers and pneumatic conveyors, to support the relocation of different kinds of materials.
• Robotics: These, too, come in numerous varieties, like automated guided vehicles, pickers, and others. Following the instructions of warehouse execution systems, these robots traverse the warehouse environment, carrying out various tasks like picking and moving goods.
• Sortation Systems (Sorters): These systems are tasked with sorting goods in accordance with pre-defined criteria. They can divert products and equipment where they need to be, controlling conveyors and other pieces of technology in the process.
• Voice Pickers: These use voice recognition technology to help guide warehouse workers. The workers wear headsets that receive information from warehouse management systems that tell them where to go and what to do.

Key Features Across Automated Control Systems

Automated control systems vary massively in their functions and capacities, but all need to share certain common characteristics. Namely, they need to have strong levels of connectivity and interoperability with other systems and solutions, so that information can flow from one system to another, uninterrupted, as well as the capacity to carry out received instructions in a timely, efficient manner.

Trends Shaping the Future of Automated Control Systems

The sphere of automated warehouse control systems is evolving all the time, developing in alignment with new technologies to become more precise, reliable, and effective. Current and upcoming trends that will shape the way warehouse control systems work in the years to come include:

• AI and Machine Learning Integration
• IoT and Connectivity Advancements
• Data Analytics and Predictive Insights
• Cloud-Based Solutions and Scalability
• Human-Machine Collaboration

AI and Machine Learning Integration

We have well and truly entered the age of artificial intelligence, with AI becoming a bigger part of many industries and systems. 

Naturally, that includes warehouse management and control systems. Many of the latest iterations have AI features, with AI bots able to analyze reams of data and issue the most appropriate instructions to optimize operations.

IoT and Connectivity Advancements

The growing importance of “Internet of Things” (IoT) is also shaping the future of warehouse and supply chain automation. More and more devices and pieces of equipment now have built-in smart and Wi-Fi functionalities, allowing them to connect, exchange information, and collaborate. 

This opens new opportunities for automated equipment control within a warehouse environment.

Data Analytics and Predictive Insights

Data analysis has always been a big part of warehouse optimization. Managers have, for years, turned to data to derive valuable insights that shape the way their warehouses work. 

Now, they have access to the most advanced analytical tools ever seen, which can dig into vast databases, spot trends, identify improvements, and even predict the future to inform upcoming strategic decisions.

Cloud-Based Solutions and Scalability

Thanks to the proliferation of cloud technology, today’s warehouse automation systems are more scalable than ever. Even as warehouses expand or become more complex, with new layers and levels of integrated equipment, managers can simply broaden their cloud storage and connectivity plans, scaling up their services to suit their growing needs.

Human-Machine Collaboration

Despite the many advancements in automation in warehouse spaces, there’s still a clear and pressing need for human personnel to help manage the many systems and pieces of equipment in place. Many key trends relating to this technology focus on ways to bridge the gaps between humans and machines, helping them work more effectively together, for instance, via voice pickers.

Discover Logix WCS by BoxLogix

For warehouses aiming to take full advantage of modern automation trends, BoxLogix offers Logix WCS—a powerful, flexible warehouse control system designed to optimize high-volume operations. Built for seamless integration with your existing WMS or WES, Logix WCS features:

• Live 3D visual monitoring of warehouse equipment
• Intelligent order routing that adapts in real-time
• Full visibility into pick, pack, and ship workflows
• Predictive diagnostics and configurable automation controls

Logix WCS helps bridge the gap between automation trends and real-world implementation, enabling faster throughput, reduced downtime, and scalable warehouse performance.

Explore Logix WCS features and watch a short video overview here.

Benefits of Implementing Automated Warehouse Control Systems

As touched on earlier, automated warehouse control systems are now considered fundamental, essential elements of distribution centers. The benefits they deliver are too important to forgo. Those benefits include:

• Enhanced Operational Efficiency
• Optimized Inventory Management
• Cost Savings and ROI
• Scalability and Adaptability
• Improved Safety and Risk Mitigation
• Customer Satisfaction and Service

Enhanced Operational Efficiency

One of the clearest benefits of automated systems can be seen in productivity and efficiency. By automating tasks throughout the warehouse, you reduce the risk of bottlenecks, delays, interruptions, and human error. 

Everything simply moves faster and more effectively, with products and materials going where they need to go and orders fulfilled at record rates.

Optimized Inventory Management

Automated warehouse technology provides accurate, real-time information regarding inventory levels, which is invaluable in terms of managing stock and preventing instances of either under- or overstocking. Thanks to this, there will almost always be the right amounts of various products and supplies in stock, as warehouse managers will regularly receive alerts if stock levels are getting too low or products are overstocked.

Cost Savings and ROI

Automation technology isn’t free. It demands a certain level of initial investment. However, over time, when used correctly, automated systems pay for themselves many times over and deliver clear cost-saving benefits across the warehouse and beyond. 

They improve productivity, helping to cut out costly mistakes and reduce labor expenses, too, with rapid and impressive returns on investment.

Scalability and Adaptability

In the past, when warehouses grew or became more complex, it could be immensely difficult to manage and adapt to that growth. Nowadays, with the aid of scalable automated systems, it’s far easier. When a warehouse’s operations begin to expand, managers can simply scale up their automated solutions simultaneously to meet increasing levels of demand and distribution volume.

Improved Safety and Risk Mitigation

Warehouses are not always the safest of environments, due to the many pieces of heavy machinery, equipment, and sometimes dangerous materials traveling through them. Warehouse automation systems help to reduce the risk of accidents by controlling material handling equipment with exceptional levels of precision and reliability, minimizing human workers’ exposure to hazards.

Customer Satisfaction and Service

This ties into many of the other benefits listed above. As warehouses become more efficient, reliable, productive, safe, and speedy working environments, the end customer reaps the rewards. They receive their orders more promptly than ever, and with far fewer errors or oversights, too. 

This, in turn, aids with customer acquisition and retention, which also leads to increases in revenue and profit.

Considerations for Your Business’s Warehouse Operations

Clearly, warehouse automation systems are crucial for modern-day warehouses to succeed. However, with so many systems to choose from, it can be tricky to know where to start.

Warehouse managers are encouraged to assess their existing situations and expected future needs to ascertain which solutions to invest in, and think about other factors, such as their automation budget.

Let the BoxLogix Experts Help Your Warehouse Thrive

With the power of automation, warehouses become faster, safer, and dramatically more productive. But results can vary, depending on which systems you invest in and how you deploy them. For best results, it’s wise to work with warehouse automation experts, like the team at BoxLogix, who have years of experience in elevating warehouse operations with technology.

Contact us today to learn more.

Frequently Asked Questions (FAQs)

What are automated warehouse systems?

Automated warehouse systems are technologies and software solutions designed to streamline and optimize warehouse operations. They handle tasks such as inventory management, order picking, and material movement, helping to improve efficiency, accuracy, and speed throughout the facility.

What is WMS automation?

WMS automation refers to the use of a Warehouse Management System to automate core processes like inventory tracking, receiving, picking, and shipping. These systems help reduce manual labor and human error while providing real-time visibility into warehouse operations.

What is an example of warehouse automation?

A common example of warehouse automation is the use of automated storage and retrieval systems (AS/RS), which utilize robotic cranes to move goods in and out of storage locations. Other examples include conveyor systems, robotic pickers, and voice-directed picking technologies.

Can a warehouse be fully automated?

Yes, it is possible for a warehouse to be fully automated, especially in industries with high volumes and predictable workflows. However, many warehouses still rely on a hybrid approach, combining automation with human oversight to ensure flexibility and handle complex or exception-based tasks.