When I first entered the material handling automation industry, I leaned heavily on foundational resources from industry leaders. One that still stands out is Material Handling Handbook by Ray Kulwiec. Even today, I revisit it when I’m evaluating a facility design or working through a complex application.
One fundamental principle has always remained true: 'the product drives the solution.'
Too often, automation systems are designed to be “fit for a particular purpose.” While that may work initially, it can create challenges over time.
For example:
- Storage design is frequently dictated by product dimensions and Ti/Hi configurations.
- Packaging decisions made upstream don’t always align with downstream storage systems.
- In grocery and other sectors, ASRS become underutilized because product dimensions changed.
We’ve seen similar challenges in goods-to-person ASRS systems:
- Cube utilization vs. tote size becomes a critical constraint
- Handling methods can limit flexibility
- Changes in product mix can quickly reduce system effectiveness
As a consultant, I often compared multiple automation systems and found one key truth: matching inventory characteristics to storage technology is critical and often underestimated.
So here’s the reality: Inventory changes. Packaging evolves. Business needs shift. When that happens, a rigid system can quickly lose its value.
The Takeaway
The most important design factor isn’t just performance—it’s versatility.
Systems that can adapt to:
- Different product sizes
- Mixed handling (totes, cases, each-pick)
- Changing inventory profiles
…are the ones that deliver long-term ROI and sustainability.
Why this matters
From a customer perspective, flexibility isn’t a “nice to have”, it’s a safeguard for your investment. If your automation can evolve with your product, your operation stays efficient. If it can’t, you’re redesigning, or replacing, sooner than expected.
Take a look at Freespace Robotics and consider how a more adaptable approach to automation could align with your inventory today and tomorrow.