Warehouse productivity isn''t just determined by how quickly orders are picked. It''s also shaped by how much time workers spend travelling between storage locations. In many facilities, that travel accounts for a significant share of the picking process, limiting throughput and increasing labour demands.
As a trusted partner in warehouse automation, robotics, and material handling solutions, MTLI Group helps businesses design and implement systems that eliminate these inefficiencies. One of the most effective approaches is goods to person automation, which brings inventory directly to operators instead of sending workers across the warehouse floor.
In this guide, we''ll explain how goods-to-person automation works, its key benefits, the technologies behind it, and why more Canadian warehouses are making it part of their long-term warehouse automation technology strategy.
The Walking Problem Nobody Talks About Enough
Picture a warehouse where staff spend nearly half their shift walking instead of picking. That is the reality in many facilities still relying on traditional shelving and manual picking routes. Every trip down an aisle adds time to the fulfillment process, reducing productivity without adding value.
The impact rarely appears as a single line item on a budget. Instead, it shows up through lower daily throughput, increased worker fatigue, higher labour costs, and missed shipping windows during peak periods. These ongoing inefficiencies are one of the biggest reasons warehouses are rethinking how inventory moves through their facilities.
Automation adoption across Canada reflects this shift. According to a Statistics Canada report on robotics technology adoption, manufacturers reported the highest adoption of robotics technologies. It is 8.4 %, nearly three times the national average of 2.0 %. As automation becomes more common, reducing unnecessary travel is increasingly viewed as a practical way to improve warehouse performance.
What Goods to Person Automation Actually Does
Goods to person automation changes one of the most time-consuming parts of warehouse operations. Instead of sending workers across the facility to retrieve inventory, the system automatically brings storage units, shelves, or pods to a fixed picking station. Employees stay in one location while the inventory comes to them, creating a faster and more efficient picking process.
This simple shift transforms day-to-day warehouse operations in several ways:
- Reduces travel time by bringing inventory directly to the operator instead of requiring long walks between storage locations.
- Increases picking speed by keeping workers focused on fulfilling orders rather than moving around the warehouse.
- Improves accuracy by guiding operators to the correct item and quantity through software-driven instructions.
- Reduces physical strain with ergonomic picking stations that minimize walking, reaching, and repetitive movement throughout the shift.
Together, these improvements help warehouses increase throughput, improve order accuracy, and create a more productive working environment without simply asking employees to work faster.
How Goods-to-Person Systems Work in Practice
Goods-to-person systems typically rely on one of a few core technologies. Automated storage and retrieval systems move bins or pallets to a picker. Shuttle systems run along racking to deliver stored items quickly. Robotic pod systems, often seen in fulfillment centres, lift entire shelving units and carry them to a stationary operator.
A few things these goods to person automation systems share in common:
- Inventory location managed by software, not memory
- Picking stations designed for speed and ergonomics
- Continuous inventory tracking as items move
MTLI''s ASRS company team designs these systems around a facility''s actual order profile, rather than a generic template that ignores how a specific warehouse actually operates.
Comparing Traditional Picking to Goods-to-Person Models
The difference between traditional picking and goods to person automation goes beyond replacing manual travel with automation. It changes how orders move through the warehouse, how employees perform their work, and how efficiently the facility operates overall.
The table below highlights some of the key differences.
| Factor | Traditional Picking | Goods-to-Person Automation |
|---|---|---|
| Travel time | High, staff walk to inventory | Minimal, inventory comes to staff |
| Picking accuracy | Depends on staff memory | System-confirmed, higher accuracy |
| Staff fatigue | Higher, long walking routes | Lower, fixed picking stations |
| Throughput per shift | Lower | Significantly higher |
Most operations managers see the biggest gains in throughput and accuracy within the first few months of switching over. Although the full picture usually takes a full peak season to confirm.
Automated Picking Solutions Built for Order Complexity
Not every warehouse handles the same kind of order. Some manage large pallet quantities. Others fulfill single-item e-commerce orders all day long. Automated picking solutions need to match this complexity, not force every order type through the same process.
Different order profiles require different goods to person automation approaches:
- High-volume, single-item orders: Goods-to-person robotics can significantly improve speed and accuracy by bringing inventory directly to operators, reducing travel time and increasing picks per hour.
- Large case or pallet-based orders: Conveyor systems and automated material handling solutions are often better suited for moving heavier loads efficiently through defined picking zones.
- Mixed SKU environments: Hybrid automation solutions can combine robotics, conveyors, and intelligent software to handle changing demand patterns without creating bottlenecks.
Choosing the right system starts with understanding your order volume, product variety, picking methods, and future growth plans. Investing in automation that matches your operation helps avoid costly redesigns and ensures your warehouse can scale efficiently as demand changes.
Robotics on the Warehouse Floor
Robotics are transforming how modern distribution centres manage picking, movement, and daily operations. Autonomous mobile robots (AMRs) can transport shelving units, inventory, or goods directly to workers, reducing unnecessary walking and allowing teams to focus on faster, more accurate order fulfilment. Unlike traditional fixed automation, robotic systems can be expanded gradually by adding more units as demand grows, without requiring major changes to the warehouse layout.
Canada''s public sector has backed this shift directly. Innovation, Science and Economic Development Canada contributed multimillion-dollar funding toward next-generation robotic warehouse technology developed by a western Canadian firm. This is a sign that this technology has moved well past the experimental stage.
Facilities exploring this path often start with a pilot zone before expanding further. MTLI Group support this step-by-step approach. We help businesses test automation in real working conditions before moving toward a full-scale deployment.
Warehouse Automation Technology Beyond the Picking Station
Warehouse automation technology extends well past the picking process itself. A fully connected system helps streamline the entire order journey, from inventory movement to final shipment. Key technologies in AMR warehouse robots solutions include:
- Sortation systems: Direct completed orders to the correct packing or shipping lanes quickly and accurately.
- Conveyor networks: Move totes, cartons, and materials between warehouse zones with minimal manual handling.
- Automation software: Provides real-time visibility into inventory, order progress, and overall facility performance.
This connected approach matters because goods-to-person systems rarely operate in isolation. They deliver the best results when they are part of a larger automation ecosystem. When picking, sorting, and shipping technologies work together, warehouses can reduce delays, improve accuracy, and create a more efficient operation from end to end.
Electrical Infrastructure Behind Automated Picking
Automated picking systems draw significant power, especially robotic and conveyor-based platforms running continuously through a shift. Facilities upgrading from manual to automated picking often underestimate this electrical demand until installation is already underway.
Working with an electrical automation company early in the planning process avoids this problem. Proper power planning ensures picking stations, robotics, and conveyor systems all run reliably, even during peak volume periods when every station is active at once.
Installation Quality Determines Long-Term Reliability
Goods-to-person systems involve precise mechanical alignment. Shuttle rails, conveyor sections, and robotic charging stations all need accurate installation to function correctly over years of continuous use, not just during initial testing. Even small alignment or integration issues can lead to downtime, reduced efficiency, and higher maintenance costs.
Key installation considerations include:
- Accurate equipment alignment: Shuttle rails, conveyors, and robotic pathways must be installed precisely to prevent performance issues.
- Seamless system integration: Automation equipment needs to connect properly with warehouse software and control systems.
- Proper testing and calibration: Every component should be checked before launch to ensure reliable operation.
- Future service planning: Installation should support easy maintenance and future expansion as warehouse needs grow.
With the right installation approach, automated systems can deliver reliable performance, fewer disruptions, and a stronger return on investment over the long term.
Space Planning for Goods-to-Person Layouts
Goods-to-person systems change how a facility uses vertical and horizontal space. Traditional aisle-based storage often gets replaced with denser, taller storage structures designed around the automation itself, rather than around human walking paths.
A few layout considerations worth reviewing early:
- Ceiling height needed for shuttle or robotic storage systems
- Floor load ratings for dense, automated storage structures
- Clear paths for maintenance access around moving equipment
Facilities planning a larger footprint change often work with a commercial general contractor to make sure structural elements support the new layout before automation gets installed.
Staff Roles Shift, They Don''t Disappear
A common concern among operations managers is what happens to staff once automation takes over picking. In practice, roles shift rather than disappear. Staff move from walking pickers to station operators, quality checkers, and system monitors, work that is often less physically demanding.
Training staff for these new roles matters just as much as the technology itself. A well-run automated picking station still depends on an attentive operator who can catch errors, clear minor jams, and keep the workflow moving smoothly through a full shift. Facilities that invest in this training upfront tend to reach full productivity noticeably faster than those that treat the rollout as purely a hardware project.
Measuring the Return on Goods to Person Automation
Operations managers evaluating this investment should track a few specific metrics before and after implementation. Picks per hour per worker shows the direct productivity gain. Order accuracy rates reveal whether errors dropped as expected. Labour cost per order often shows the clearest financial picture, since it captures both speed and accuracy improvements together.
Most facilities see measurable gains within the first quarter of operation, though full return on investment typically plays out over one to two years, depending on order volume and the scale of the initial deployment. Facilities that track these numbers consistently from day one tend to make smarter decisions about where to expand the system next.
Bringing It All Together
Goods to person automation changes the fundamental math of picking. Less walking means more picking, and more picking means higher throughput without adding headcount. Strong goods-to-person systems paired with the right automated picking solutions turn a facility''s biggest hidden cost, wasted travel time, into its biggest efficiency gain.
Logistics companies exploring this shift do not need to automate everything at once. A single pilot zone, built on solid warehouse automation technology, proves the case before a larger rollout. MTLI works alongside operations teams across Canada to plan and install exactly this kind of staged transition. Get in touch today to start building your automation strategy.