Pre-Automation Q&A: 10 Things You Must Do Before Calling a Vendor

You're ready to explore automation. But before you pick up the phone, there's work to do. The companies that succeed with automation don't just find the right vendor—they come prepared. Here's what to do first.

Q1: "Should I clean up my data before automating?"

A: Yes. Garbage in, garbage out.

What to clean:

• SKU master data (dimensions, weights, codes)

• Inventory counts (cycle count problem areas first)

• Supplier lead times (accurate = better planning)

• Customer order patterns (identify peaks, seasonality)

Why it matters: Your automated system will be only as good as the data you feed it. Bad data = bad decisions.

How long: 2-4 weeks for most warehouses.

Q2: "Do I need to standardize my pallets and packaging?"

A: Ideally, yes. But not perfectly.

What helps:

• Standard pallet sizes reduce complexity

• Consistent case dimensions improve shuttle fit

• Clear labeling (barcodes) enables automation

What you can keep:

• Some variation is fine

• Modern systems handle mixed sizes

• Don't let perfection be the enemy of progress

The test: If 80% of your flow is standard, you're ready. Handle the 20% exceptions manually or with special cases.

Q3: "Should I map my current processes first?"

A: Absolutely. You can't improve what you don't understand.

What to map:

• Receiving workflow (from truck to putaway)

• Storage logic (where do things go and why?)

• Picking workflow (how do orders get filled?)

• Replenishment triggers (when do you refill picking zones?)

• Returns process

How to do it: Walk the floor with a notebook. Follow one order from arrival to shipment. Note every touch, every wait, every decision.

Output: A simple flowchart. It doesn't need to be perfect. It just needs to be honest.

Q4: "Do I need to know my exact SKU velocity?"

A: Yes. This is critical.

What you need to know:

• Which SKUs are A-movers (fastest 20%)

• Which are B-movers (middle 60%)

• Which are C-movers (slowest 20%)

Why it matters: Your automation design will treat each group differently. A-movers go closest to pick stations. C-movers go to dense storage.

If you don't have this data: Run a sales report for the last 12 months. Rank SKUs by units moved. It takes a day. Do it.

Q5: "Should I involve my team before I talk to vendors?"

A: Yes. This is the most skipped step—and the most costly.

What to do:

• Tell them you're exploring automation

• Explain why (growth, service, their wellbeing)

• Ask for their input (they know the pain points best)

• Address fears directly ("No one is losing their job")

Why it matters: The best system fails if your team resists it. Involve them early. They'll become your champions instead of your obstacles.

When to do it: Before you issue any RFQ or make any vendor calls.

Q6: "Do I need to measure my warehouse accurately?"

A: Yes. Guessing leads to problems.

What to measure:

• Clear height at multiple points (floors aren't always level)

• Column locations and spacing

• Door locations and sizes

• Electrical panel locations

• Floor flatness (critical for tall ASRS)

How to do it: Get a laser measure. Spend 2 hours walking the warehouse. Or hire a surveyor for critical measurements.

Why it matters: A system designed on bad measurements won't fit. You'll pay for change orders.

Q7: "Should I calculate my current cost per order?"

A: Yes. This is your baseline ROI metric.

What to include:

• Labor (direct and indirect)

• Space (rent + utilities allocated)

• Errors (returns, reships, discounts)

• Equipment (forklifts, maintenance)

The formula: Total annual warehouse cost ÷ total annual orders

Example: $2Mannualcost÷500,000orders=$4 per order

Why it matters: After automation, you'll measure the new cost per order. The difference × order volume = your annual savings.

Q8: "Do I need to know my peak capacity?"

A: Yes. Underestimating peaks is a common mistake.

What to calculate:

• Maximum orders processed in one day (historical)

• Maximum orders you've turned away (lost opportunity)

• Maximum labor you've used (overtime, temps)

Why it matters: Your system needs to handle peak, not just average. Design for the surge, not the lull.

The test: If your peak is 3x your average, your system needs 3x capacity at peak. Shuttles scale for this. Design for it.

Q9: "Should I visit an automated warehouse first?"

A: Strongly recommended. Seeing is believing.

What to look for:

• How do workers interact with the system?

• What happens when something goes wrong?

• How clean is the operation?

• What would you ask the manager?

If you can't visit: Request a video tour. Most vendors (including us) can arrange a virtual walkthrough.

Why it matters: Videos and brochures are curated. Real operations show reality.

Q10: "What's the one thing companies forget to do?"

A: Define success before they start.

Don't just say "automate the warehouse." Say:

• "Reduce picking labor by 40%"

• "Increase storage density by 60%"

• "Eliminate order errors"

• "Cut cold storage energy by 30%"

Write it down. Share it with your team. Use it to evaluate vendors. A clear target is the first step to hitting it.

Your Pre-Automation Checklist

The Bottom Line

Preparation separates successful automation from expensive mistakes. Companies that do this homework get better proposals, faster implementations, and higher ROI.

The vendors will still be there when you're ready. Take the time to get ready.

Ready to start your prep work? We can help you think through what matters for your specific operation.