In warehouse and distribution environments, uptime directly affects revenue. When automated systems go offline, operations come to a stop. That means missed deadlines, disrupted workflows, and potential losses. For companies using systems like conveyors, AS/RS, AMRs, or vertical lift modules, maintaining operational readiness is essential.
At BoxLogix, we help companies avoid those costly disruptions through strategic preventative maintenance. Regularly scheduled service and inspections can help your automation run smoother, last longer, and deliver the return on investment your business depends on.
Preventative maintenance is a proactive service approach where equipment is inspected, cleaned, adjusted, or replaced before it fails. It is the opposite of reactive maintenance, where problems are fixed only after something goes wrong.
A strong preventative maintenance program includes:
Regular inspection of mechanical and electrical components
Lubrication of moving parts to prevent wear
Calibration of sensors, control systems, and equipment
Cleaning dust and debris that may interfere with system performance
Safety system checks, including emergency stops and sensors
Software health checks and control panel diagnostics
In automated warehouses, preventative maintenance applies to systems like:
Conveyor systems and motorized rollers
Pallet shuttles and AS/RS systems
Autonomous mobile robots (AMRs)
Warehouse control software (WCS) and PLCs
Vertical lift modules (VLMs)
Few things are more disruptive than unplanned downtime. Whether the issue is a stuck conveyor or a robotic system failure, unexpected breakdowns lead to delays. A preventative approach helps identify and resolve small issues before they grow into bigger, more expensive problems.
Automation is a significant investment. Preventative maintenance protects that investment by reducing wear and tear. With proper service, systems run more smoothly and last longer. This means fewer replacements and less capital spent over time.
Throughput is the backbone of your operation. When a key component fails, order fulfillment slows down. Preventative maintenance supports your throughput goals and helps you meet delivery windows and service level agreements.
Many automation systems operate near employees or in complex environments. If safety devices or warning systems are not functioning correctly, your team may be exposed to unnecessary risk. Regular maintenance ensures all safety systems are tested and compliant.
Preventative maintenance requires time and resources, but it is far less costly than emergency repairs. A scheduled service visit is more affordable than expedited parts, overtime labor, or extended downtime. Over time, preventative maintenance leads to fewer disruptions and more predictable budgeting.
There is no universal rule, but most facilities follow one of the following cycles:
Monthly visual inspections and minor service
Quarterly checks of critical mechanical and control systems
Annual system audits to assess wear, calibration, and lifecycle planning
The right frequency depends on several factors, including:
Runtime hours
Environmental conditions such as temperature, moisture, or dust
Equipment type and manufacturer recommendations
At BoxLogix, we work with each client to build a custom maintenance plan based on their facility and operational needs.
Conveyors often run non-stop and are subject to physical stress. Chains, belts, motors, and bearings should be inspected regularly. Accumulation zones and diverters should also be tested to ensure consistent flow.
Automated storage and retrieval systems rely on precision. Regular inspections should include the mechanical drive systems, sensors, shuttle paths, rail alignments, and lift systems.
Mobile robots rely on battery performance, sensor calibration, and software integrity. Maintenance includes cleaning LiDAR units and cameras, testing stopping behavior, checking battery health, and running diagnostics for the robot’s pathfinding system.
The best preventative maintenance programs are proactive and personalized. At BoxLogix, we offer:
Custom-built maintenance schedules
On-site technician service
Equipment-specific checklists and reports
Detailed service logs and recommendations
Remote diagnostics and support
Strategic advice based on lifecycle, performance, and operational goals
We do more than just service your equipment. We help you use your system data to optimize operations, reduce risk, and plan for long-term growth.
Preventative maintenance should not be an afterthought. It should be part of your warehouse’s long-term strategy. By investing in regular upkeep, you can ensure your systems stay reliable, efficient, and safe.
If you're ready to explore a preventative maintenance program for your warehouse automation system, contact BoxLogix. We will work with your team to assess your current system, identify gaps, and create a plan that keeps your operation moving forward.