Why automation is more important today than ever

Many companies are facing a major challenge: qualified personnel for warehousing and logistics are becoming increasingly difficult to find. High staff turnover, a shortage of skilled workers and increasing demands on process reliability and quality are commonplace in many warehouses. According to IAB statistics, there were over 60,000 vacancies in warehouse logistics in 2025, and around 43% of German companies state that they have considerable difficulties in recruiting, which further increases the pressure on the industry. Looking just a few years into the future, this situation becomes even more challenging. In view of this situation, automation in warehouses is increasingly coming into focus – as the key to making processes more efficient and reducing the workload of employees.

Automation is no longer a topic for the future – it is already a reality. According to a study by MIT and Mecalux, 60% of warehouses worldwide use AI or automated systems, and around half of companies have automated at least 50% of their processes. At the same time, around 75% of logistics companies are planning further investments in robotic solutions to increase efficiency and competitiveness. The dream of a dark warehouse is therefore realistic if it is implemented strategically and step by step. However, not every solution is suitable for every company. The key question is: which automation solutions make sense and are cost-effective for your warehouse – and how can you get the most out of targeted investments?

The path to a dark warehouse requires more than just technology – it needs a clear strategy, a clear goal and tailor-made solutions for your company. It’s a marathon, not a sprint: only those who proceed step by step will achieve efficiency and automation at the highest level in the long term.

Phillip Carl, Senior Manager

The path to the Dark Warehouse

A dark warehouse is planned in two overarching phases: Analysis phase and Implementation phase, each of which contains several steps.

Analysis phase

1. Consider all scenarios
   The first step is to analyze all current and future processes in the warehouse. It is important not to commit to specific technologies or manufacturers too early. Focusing too quickly on a supposedly “perfect system” can lead to the warehouse not being optimally designed. The first step is to sketch out the ideal world – what would the perfect dark warehouse look like? Only then is it checked what is possible in reality.
2. Plan step by step and with an open mind
   Work from the outline to the detail: What do you want to achieve? Which processes need to be supported? Only then is it worth taking a look at the market in order to select suitable providers and technologies. A roadmap should also be drawn up to show how implementation can take place step by step.
3. The entire process chain
   Automation must not be viewed in isolation, but must be planned as an overall system. Only a well thought-out master plan can ensure that all processes interlock smoothly. This means that automation can be further expanded at a later date when more budget is available or technologies become cheaper.

Implementation phase

Involve employees
The transformation to a dark warehouse is a journey, not a sprint. Long-serving employees are valuable sources of expertise. If they are not involved, this can lead to resistance or loss of staff. Through active involvement and further training, employees can take on new tasks and grow with the change.

Check robustness
A dark warehouse must be resistant to disruption. What happens in the event of a power failure, IT problems or sudden supply bottlenecks? These scenarios must be included in the planning right from the start in order to avoid lengthy downtimes.

Stay realistic
Not every process can be automated immediately. Different product sizes, materials or task complexity require graduated automation. Nevertheless, you should try to achieve maximum automation with the available budget. And even if not everything is possible today, automation can be expanded in the future as soon as resources or technologies become available.

Securing the future – before the skills shortage strikes

Companies planning the move to automated warehouses today are not only securing a competitive advantage, but are also arming themselves against the growing shortage of skilled workers. A well-thought-out master plan that takes robustness, realism and employee integration into account is the key to turning the vision of a dark warehouse into a sustainable reality. In this way, development remains flexible: further automation can be added later if required, when more resources or new technologies are available.

Summary

A dark warehouse offers companies a competitive advantage through automation and efficient processes. Getting there requires strategic planning: first sketch out the ideal world, then realistically examine which solutions can be implemented and create a roadmap. The maximum amount of automation should be implemented within the available budget, while involving employees and considering the overall process chain. In this way, the system remains robust, future-proof and flexible for later expansions when more resources or new technologies become available.