Buying a shuttle system—whether 4-Way Shuttles or Pallet Shuttles—is a major decision. This checklist walks you through everything you need to consider, from your own operations to vendor selection.*
Section 1: Know Your Own Operation (10 Questions)
Before you talk to any vendor, answer these.
| # | Question | Your Answer |
|---|---|---|
| 1 | What is your single biggest pain point? (Space / Labor / Speed / Accuracy / Energy) | _____ |
| 2 | What is your average daily pallet/case volume? | _____ |
| 3 | How many SKUs do you currently manage? | _____ |
| 4 | What is your warehouse's clear height? | _____ |
| 5 | What percentage of your inventory is full pallets vs. cases/individual items? | _____ |
| 6 | What is your current picking error rate? | _____ |
| 7 | What is your annual warehouse labor turnover? | _____ |
| 8 | How much would you save by delaying or avoiding a warehouse expansion? | _____ |
| 9 | What is your peak-to-average order ratio (e.g., 3x volume during holidays)? | _____ |
| 10 | Do you need FIFO compliance for expiration dates? | _____ |
Section 2: Which Technology Fits? (5 Questions)
*Use these to determine whether you need a 4-Way Shuttle, a Pallet Shuttle, or both.*
| # | Question | If YES → |
|---|---|---|
| 11 | Do you primarily store full pallets? | Consider Pallet Shuttle |
| 12 | Do you primarily pick cases or individual items? | Consider 4-Way Shuttle |
| 13 | Do you have both bulk storage AND case picking? | Consider Both |
| 14 | Are you in cold storage with high energy costs? | Pallet Shuttle (priority) |
| 15 | Do you have thousands of SKUs with high order variability? | 4-Way Shuttle (priority) |
Section 3: Vendor Evaluation (10 Questions)
Ask these of every vendor you consider.
| # | Question | What a Good Answer Sounds Like |
|---|---|---|
| 16 | How many systems have you installed in my industry? | "Here are 3+ examples with similar profiles." |
| 17 | Can I speak to customers from 3+ years ago? | "Yes, here are their contact details." |
| 18 | Is your WMS/WCS developed in-house? | "Yes, we control the full stack." |
| 19 | What is your typical response time for support? | "24/7, with <2 hours for critical issues." |
| 20 | Do you offer remote monitoring? | "Yes, standard, 24/7." |
| 21 | What spare parts should I keep on hand? | A specific list based on your configuration |
| 22 | How long from contract to go-live? | A realistic timeline (3-6 months typical) |
| 23 | Will my warehouse need to shut down during installation? | "No, we use a phased zone approach." |
| 24 | What training do you provide? | "On-site, hands-on, until your team is confident." |
| 25 | What's not included in your quote? | A clear, written list |
Section 4: ROI & Financials (5 Questions)
Make sure the numbers work.
| # | Question | What to Look For |
|---|---|---|
| 26 | What is the payback period for my specific operation? | 2-4 years is typical |
| 27 | Have you modeled labor, space, error, and energy savings? | All four should be included |
| 28 | What's the 5-year total cost of ownership? | Initial cost + maintenance + support |
| 29 | Can I start small and expand later? | Yes—modular, phased approach |
| 30 | Have you included hidden costs (electrical, building mods, shipping)? | Ask for a complete list |
Quick Decision Guide: Which System Is Right for You?
| Your Primary Need | Recommended System | Why |
|---|---|---|
| Store more pallets in existing space | Pallet Shuttle | 60-100% density increase |
| Reduce cold storage energy costs | Pallet Shuttle (cold-rated) | 70-90% fewer door openings |
| Speed up case/individual item picking | 4-Way Shuttle | Goods-to-person, 2-3x faster |
| Eliminate picking errors | 4-Way Shuttle | >99.99% accuracy |
| Raw materials for manufacturing | Pallet Shuttle | Dense, FIFO, reliable |
| E-commerce order fulfillment | 4-Way Shuttle | Handles SKU chaos and spikes |
| Both bulk storage AND fast picking | Both (Pallet + 4WS) | One feeds the other |
| Low ceiling (<8m) | Pallet Shuttle or 4WS (not ASRS) | ASRS needs height |
| High ceiling (>12m) with pallets | ASRS | Best use of vertical space |
Red Flags to Watch For
| Vendor Says... | What It Might Mean |
|---|---|
| "Our system works for everyone." | No deep industry expertise |
| "You don't need references." | Hiding something |
| "We'll figure out integration later." | Poor planning |
| "We guarantee 99.9% uptime." | Ask for proof from real customers |
| "We can do it in 6 weeks." | Unrealistic timeline |
Green Flags to Look For
| Vendor Does... | Why It's Good |
|---|---|
| Asks more questions than they answer | They want to understand your problem |
| Provides specific industry references | They've done this before |
| Offers a phased implementation plan | They respect your need for continuity |
| Has in-house software development | Better integration, faster fixes |
| Talks about total cost, not just price | They're thinking long-term |
Your Next Steps
Complete this checklist. Fill in your answers for Section 1.
Use Section 2 to identify which technology fits.
Use Section 3 to screen vendors.
Use Section 4 to validate the financial case.
Schedule discovery calls with 2-3 vendors who pass your screen.
The Bottom Line
You don't need to be an automation expert. You need a clear process and the right questions.
This checklist gives you both.
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