Warehouse and logistics processes are increasingly shaped by digital tools, yet in many companies, the alignment between digital systems and physical operations still presents challenges. While automation is on the rise, the reality is that only around 5% of warehousing tasks can be fully automated. The vast majority—95%—still relies on human workers.

In this context, the key challenge is not full automation but rather identifying which manual processes can and should be optimized to enhance productivity, quality, and employee well-being.

Ensuring productive and error-free warehouse operations is becoming increasingly critical due to the significant and ongoing labour shortage. A study published in January 2024 by Sapio Research, which surveyed 1,000 supply chain and logistics leaders across Europe and North America, found that 68% of respondents reported difficulties hiring warehouse employees. This shortage threatens operational efficiency and can lead to increased costs, delayed deliveries, and supply chain disruptions.

The stakes are high: according to McKinsey, logistics expenses represent 12 to 20% of a company’s revenue, underscoring the importance of streamlined processes for profitability.

Against this backdrop, many warehouses are turning to process optimization strategies—not as an alternative to the workforce, but as a way to support existing teams, improve accuracy, and raise efficiency.

One such approach is the use of Bluetooth Low Energy (BLE) beacon technology. Beacons are small, battery-powered devices that transmit signals to nearby receivers—typically mobile devices, scanners, or wearables used by warehouse staff.

By placing beacons at key process points (such as loading docks, picking zones, or sorting stations), companies can automate the confirmation of physical actions. This creates a direct link between the digital workflow and the physical process, helping to reduce manual steps and minimize errors.

The introduction of beacon technology into warehouse processes offers a range of benefits:

• Fewer Errors: By automating confirmation steps, the risk of mistakes in picking, sorting, and loading is reduced.
• Higher Productivity: Manual tasks such as barcode scanning or verbal confirmations are reduced, saving time.
• Better Ergonomics: Workers can focus on value-adding tasks without being burdened by handheld devices.
• Reliable Process Data: Automatic, time-stamped confirmations enhance transparency and traceability.
• Reduced Training Effort: Simple visual or acoustic guidance lowers the need for complex training, with no language barriers.

These improvements are particularly relevant for fast-moving sectors such as e-commerce, retail distribution, and automotive logistics.

The use of beacon technology can be integrated into various warehouse and logistics processes:

• Picking: Visual or acoustic guidance replaces manual scans, speeding up orderfulfillment and reducing errors.
• Sorting: Put-to-wall and other sorting processes benefit from clear, automatedconfirmations.
• Loading: Beacon-based systems ensure that pallets are loaded into the correct vehicles, with automatic documentation.

A key advantage of such solutions is that they typically require minimal upfront investment and no major infrastructure changes. Wireless beacons can be installed easily, and the systems are compatible with existing warehouse management systems (WMS). This makes beacon-based process optimization an accessible option for companies of all sizes—not just large-scale logistics operations.

Optimized processes also contribute to lower environmental impact by reducing incorrect shipments, unnecessary transport, and waste. This supports broader sustainability objectives while simultaneously improving operational efficiency.

In today’s logistics landscape—marked by labour shortages, rising costs, and increasing customer expectations—process optimization is key. While full automation may not be realistic for most warehouse tasks, targeted improvements using technologies such as beacons can make a measurable difference in accuracy, productivity, and employee satisfaction.

This contribution was provided by Digilo GmbH