Mobile industrial robots are becoming the unsung heroes behind many successful warehouse and plant operations. With increasing demands, tight delivery windows, and ongoing labor shortages, these autonomous machines are stepping up. In this article, we break down 30 powerful statistics shaping this shift and dive deep into what each means for your business. Whether you’re just getting started or looking to scale up, each section offers practical insights, real-world implications, and steps you can take to make the most out of mobile robotics in your facility.
1. 78% of large warehouses have implemented or are piloting mobile industrial robots
If you’re operating a large warehouse and haven’t yet explored mobile industrial robots, you’re already behind 78% of your peers. That figure alone sends a strong message—adoption is no longer a futuristic idea; it’s happening now.
Facilities are seeing the value these robots bring in handling repetitive, labor-intensive tasks such as moving inventory, transporting items between zones, or restocking shelves.
So, what does this mean for you? First, take a close look at your current operations and identify areas where human labor is being used for repetitive or low-value tasks. These are the places where mobile robots can shine.
Next, evaluate your warehouse size and complexity. Larger operations tend to benefit more from robot automation because the distances and volume make human-only workflows inefficient.
Begin with a pilot project. You don’t need to automate everything at once. Many companies start small—deploying a few robots in a single department—and scale once they see results.
Partner with vendors who provide robust support during the trial phase, especially those who help integrate with your existing warehouse management system. And most importantly, ensure your team is on board. Training and acceptance from warehouse staff can make or break the pilot phase.
2. 92% of companies report increased efficiency after adopting mobile robots
Efficiency is the core promise of automation, and with 92% of companies seeing a clear boost, mobile robots are delivering on that promise. Whether it’s shaving minutes off pick times or eliminating deadhead walking, robots help tighten workflows in ways that manual systems just can’t.
To harness this kind of efficiency, you first need to measure where your inefficiencies lie. Are pickers walking too far between tasks? Are items piling up at one station while others sit idle?
Mobile robots can create a smooth, continuous flow of goods that keeps everything moving in sync.
But just adopting robots isn’t enough—you need to rethink your workflows to complement them. For example, reorganize your floor plan to minimize traffic conflicts between people and robots.
Assign robots to zones with high traffic or repetitive routes. And don’t overlook software. Efficiency gains often come from better coordination between your robot fleet and your WMS.
Keep tracking performance post-deployment. Set specific KPIs like pick speed, delivery times, and order accuracy. Revisit your layout and robot routes often. Automation isn’t “set it and forget it.” The best-run warehouses are constantly tweaking and improving based on real-time data.
3. 68% of distribution centers plan to increase their mobile robot fleet within 2 years
This stat shows us that mobile robot adoption is not just a one-time investment—it’s a growing trend. Once companies see the benefits, they’re eager to scale. And for good reason.
As order volumes grow and customer expectations rise, mobile robots offer a scalable solution without the long timelines and costs associated with hiring and training new employees.
If you’re considering expanding your robot fleet, the key is to do it strategically. Don’t just add more robots—optimize how you use them. Use data from your current fleet to identify high-performing zones.
Invest in software upgrades that allow more complex coordination between robots. This helps prevent congestion and keeps your operations fluid.
Plan ahead for infrastructure needs. Larger fleets may require better Wi-Fi coverage, additional charging stations, and more robust fleet management systems. Talk to your provider about these needs early so you can scale without disruption.
Also, consider your long-term strategy. Will you use robots only for transport, or could they handle picking or packing in the future?
Having a roadmap helps you invest in the right hardware and software today, saving you from costly replacements tomorrow.
4. 45% reduction in manual labor costs is achieved on average with mobile robot adoption
Saving money on labor doesn’t mean replacing your entire team—it means reallocating human effort toward high-value tasks.
With a 45% reduction in manual labor costs, companies are seeing real bottom-line benefits from using mobile robots. That doesn’t just include wages; it covers reduced training, lower turnover, and fewer injuries too.
If you’re aiming to cut labor costs, look at where you’re using people for low-skill, high-volume tasks. That’s your automation sweet spot. Robots don’t get tired, don’t need breaks, and don’t call in sick.
They keep going, day and night, helping you maintain output even when staffing is tight.
But be thoughtful. Automation should empower your workers, not replace them. Train your staff to manage and work alongside robots. Some might become robot supervisors or troubleshooters. Others could move into quality control or customer service roles.
And don’t forget to communicate the purpose of automation to your team. When employees understand that robots help reduce their physical strain and free them up for more meaningful work, resistance tends to fade.
5. 62% of warehouses use mobile robots primarily for material transport
Material transport is one of the most time-consuming and physically demanding parts of warehouse work. That’s why it’s the number one use case for mobile robots. If you’re still relying on manual carts or forklifts for this task, there’s a better way.
By using robots for material transport, you instantly free up people for more complex tasks like quality checks or custom packaging. Robots can shuttle inventory from receiving to storage, from storage to picking zones, or between workstations.
This not only speeds things up but also reduces product damage and increases safety.
To get started, map out your current transport workflows. Where are things slowing down? Where are people walking long distances or making multiple trips? These are your first targets for automation.
Also, evaluate the physical environment. Are your aisles wide enough? Is your floor smooth and free of debris? Mobile robots rely on clear paths and consistent surfaces to operate effectively. You might need to make small changes to your layout or cleaning schedule to ensure optimal performance.
Once in place, keep monitoring. Track how long deliveries take, how often robots idle, and how human workers are interacting with them. This helps you refine your robot fleet’s usage and ensures that you’re getting the most out of your investment.
6. 35% increase in order fulfillment speed after mobile robot integration
Speed matters more than ever. Customers expect their orders faster, and businesses that can’t keep up often lose out. A 35% boost in order fulfillment speed is a game-changer, especially when delivery windows keep shrinking.
How do robots deliver this kind of speed? They move without breaks, delays, or distractions. They’re precise, consistent, and can operate in parallel with human workers without getting in the way. When you integrate them properly, they eliminate lag time between tasks and reduce bottlenecks.
To capture this speed increase, focus on creating seamless handoffs between robots and people. That means clearly defining zones where robots handle transport, and where humans focus on picking or packing. If you try to make them do too much, you’ll slow down rather than speed up.
Another tip—rethink batch processing. Many warehouses batch orders to minimize walking time. With robots handling the walking, you can shift to single-order fulfillment without losing efficiency. That often means faster turnaround times for customers.
Lastly, keep your system flexible. Fulfillment speed often depends on the ability to adapt to demand spikes or last-minute order changes. Choose robot systems that integrate with your WMS and can be reprogrammed quickly to adapt to shifting priorities.
7. 50% of mobile robot users experience ROI within 18 months
A 50% ROI rate in under 18 months is strong validation. For many businesses, mobile robots are no longer seen as a cost—they’re an investment that pays back quickly. But hitting that return window takes careful planning.
First, define what ROI looks like for you. Is it cost savings? More throughput? Fewer errors? Choose clear metrics, and benchmark your current performance. Then track how robots are impacting each area.
The biggest ROI comes when robots are used to solve the most expensive problems. For some companies, that’s labor. For others, it’s downtime, returns, or injuries. Focus on the pain points with the highest financial impact first. That’s where automation gives the quickest return.
Another tip—avoid over-automation. You don’t need robots in every corner of your warehouse to see returns. Many companies hit their ROI goals by automating just 30–50% of workflows. Be selective, and scale as you see success.
And finally, use your data. Most robot platforms provide dashboards to track productivity, travel times, idle time, and more. Watch these metrics closely. When you spot underused robots or wasted time, tweak routes or assignments to tighten up operations.
8. 81% of manufacturers cite labor shortage as a key driver for adopting mobile robots
Labor shortage isn’t going away anytime soon. Across industries, companies are struggling to fill roles, especially for physically demanding and repetitive warehouse jobs.
That’s why 81% of manufacturers are turning to mobile robots—not just for efficiency, but out of necessity.
If your facility is constantly running short-staffed, it’s time to consider automation. Start by identifying roles that are hardest to fill or keep staffed. Often these are entry-level positions with high turnover. Replacing those roles with robots creates more stability in your operations.
But robots don’t just fill gaps—they help attract better talent. When you remove the most boring or physically taxing tasks, you make your facility more appealing to job seekers.
Workers are more willing to join and stay when they know they won’t be walking 12 miles a day or lifting heavy loads nonstop.
Also, think long term. The demographic trends show a declining pool of available warehouse labor. If you’re relying solely on hiring to grow your output, you’ll hit a wall. Robots offer a scalable path forward. As demand increases, you can scale up your fleet without worrying about staffing bottlenecks.
Start with a hybrid approach. Use robots to support your existing team, not replace them. Train workers to oversee and interact with robots. This builds a more flexible, tech-friendly workforce that’s ready for the future.
9. 28% of warehouse floor space is optimized through robot-assisted layout changes
Mobile robots don’t just move boxes—they change how you use space. In many cases, companies can reclaim up to 28% of warehouse floor area simply by redesigning layouts to fit robotic workflows.
That extra space can mean more inventory, faster movement, or expanded operations—all without moving buildings.
The key here is to let robots drive your layout decisions. Unlike forklifts or manual carts, robots are smaller, more agile, and need less clearance. That means you can reduce aisle width, tighten workstations, or move stock closer to high-demand zones.
To get started, map your current layout. Measure aisle widths, identify choke points, and look at the paths people take throughout the day. Then run simulations or consult with your robot provider to design a layout that supports smoother traffic flow for both humans and robots.
Don’t just think about the main floor. Look at vertical space too. When you optimize horizontal flow, you can often change how you use vertical storage, freeing up even more capacity.
Be willing to experiment. You might need to rearrange racks, move packing stations, or shift receiving docks to get the most from your robots. These changes can be disruptive at first, but the payoff in efficiency and capacity makes it worthwhile.
10. 39% reduction in workplace injuries in facilities using mobile industrial robots
Workplace injuries aren’t just costly—they hurt morale, increase turnover, and cause unpredictable downtime. That’s why a 39% reduction in injuries from mobile robot use is such a big deal. By taking over repetitive lifting, walking, and transporting tasks, robots reduce the strain and risk on your team.
Start by looking at your injury records. Where do accidents happen most often? Is it slips and falls? Overexertion? Back strain from lifting? These are the areas where mobile robots can make the biggest safety impact.
For example, if workers are hauling bins from one end of the plant to another, a robot can handle that instead. If people are using forklifts in high-traffic zones, switching to smaller, autonomous robots reduces the risk of collisions.
Robots also bring consistency. They follow programmed routes, don’t rush, and stop when something blocks their path. That predictability makes the whole environment safer for everyone.
But you’ll still need a plan. Introduce safety training for both your robot fleet and your team. Set clear traffic patterns, use signage to guide flow, and make sure everyone knows what to expect from the robots.
Over time, a safer environment means fewer disruptions, lower insurance premiums, and happier employees. And when people feel safe at work, they tend to stay longer—adding even more value to your investment.
11. 63% of mobile robot deployments are in facilities over 100,000 square feet
Large spaces come with large challenges—long travel times, inefficient item movement, and scattered storage zones.
That’s why 63% of mobile robot deployments happen in facilities over 100,000 square feet. In big warehouses or plants, mobile robots are not just helpful—they’re essential.
If you operate in a large footprint, human workers spend a good chunk of their shift walking. That adds up to wasted time, higher fatigue, and slower operations. Robots change that.
They handle the long hauls, while people stay focused in high-value zones. The result? Better productivity and less wear and tear on your team.
To make the most of robots in a large facility, invest in smart routing software. The larger the space, the more important it is to minimize congestion and idle time.
Your robots should be programmed to choose the most efficient paths, avoid blocked zones, and even work around temporary obstructions like pallets or parked carts.
Another key area is zoning. Divide your facility into logical sections and assign robots to handle transport between those zones. This prevents robots from traveling across the entire floor unnecessarily, which eats up battery life and delays deliveries.
Also, review your communication infrastructure. In large spaces, Wi-Fi dead zones or spotty connections can disrupt robot operations. Make sure your network is strong and consistent across the whole building.
You may need to install additional access points or upgrade to industrial-grade routers.
12. 87% of adopters report improved inventory accuracy with mobile robots
Inventory accuracy is one of those things that quietly make or break your business. If your system says you have something but it’s not where it should be, everything from picking to customer satisfaction takes a hit.
That’s why 87% of companies using mobile robots report improved accuracy—and that’s a powerful advantage.
So how do mobile robots help here? First, they reduce human error. Manual transport often leads to misplacement, skipped scans, or double-handling. Robots follow the same process every time, logging each move with precision.
When paired with barcode or RFID scanners, they ensure items are stored and retrieved accurately.
Another bonus is that robots help enforce system discipline. When every movement is recorded and tracked in real time, your warehouse management system becomes a true source of truth. That means fewer surprises during audits and less time spent hunting down missing items.
To get these benefits, you’ll need proper integration between your robots and your WMS or ERP system. Data should flow both ways—robots should receive accurate job assignments, and your system should get live updates on every task completed.
Train your team to work within this automated framework. Encourage proper scanning, avoid bypassing the system, and ensure returns and exceptions are handled correctly.
When people and robots work in sync, your inventory data becomes much more reliable—and that leads to better forecasting, less overstock, and higher fill rates.
13. 55% of warehouse managers cite scalability as a top benefit of mobile robots
In today’s market, flexibility is everything. Orders spike. SKUs multiply. Customer expectations shift overnight. That’s why 55% of warehouse managers point to scalability as one of the biggest reasons to invest in mobile robots.
Scalability means being able to grow without hitting a wall. With mobile robots, you can easily add more units as your business expands. There’s no need for major construction or massive hiring waves.
You simply deploy more robots—and they join your existing fleet with minimal disruption.
To scale effectively, start with a robot-friendly layout. Plan charging areas, walking paths, and buffer zones where robots can wait between tasks. As your fleet grows, you’ll need this space to prevent jams and keep movement fluid.
Next, invest in a fleet management system that can handle scale. The more robots you add, the more complex the coordination becomes. Good software can assign tasks, balance loads, and prevent traffic jams without manual input.
Also, think about scalability in terms of task variety. Many companies start by using robots for transport. But later, they expand into picking, kitting, or even inspection tasks.
Choose a platform that supports this kind of growth so you can expand vertically, not just horizontally.
Lastly, tie your robot strategy to your business goals. If you expect seasonal demand or rapid growth, prepare to scale up quickly. Keep extra units on standby or lease them short term. The more prepared you are, the smoother your scaling journey will be.
14. 73% of global AMR (Autonomous Mobile Robot) installations are in manufacturing and logistics
It’s no coincidence that manufacturing and logistics are leading the way in mobile robot adoption.
With 73% of global installations happening in these sectors, it’s clear that the return on investment and operational gains are strongest where speed, precision, and volume matter most.
In manufacturing, robots help move parts between workstations, deliver tools, or transport finished goods to packing areas. They eliminate bottlenecks and ensure production lines keep flowing. In logistics, they’re used for picking, sorting, restocking, and order staging.
So what can you learn from these industries? Start by identifying repetitive transport tasks. These are prime targets for automation. Then look at your workflows—can they be broken into modular stages where robots assist between steps?
Next, evaluate how much time and labor you’re spending on simple movement. In many facilities, this can be over 30% of total labor hours. That’s a huge opportunity to increase output without increasing headcount.
You’ll also want to benchmark against peers. What are similar businesses doing with automation? Are they using robots for last-mile order staging, or internal transfers between buildings? Look at case studies and attend industry events to stay ahead.
Finally, stay connected to your robot vendor’s roadmap. As more AMRs hit the market, features like better AI navigation, obstacle avoidance, and cloud-based fleet management will continue to evolve. Being early to adopt these improvements gives you a competitive edge.
15. 41% of plants use mobile robots for inter-departmental transport
Factories and plants are complex environments with multiple departments—assembly, quality control, packaging, storage, and more. Moving goods between them can create friction, delays, or safety risks. That’s why 41% of plants now use mobile robots to handle inter-departmental transport.
In these settings, robots aren’t just delivering parts—they’re linking the flow of the entire facility. They ensure that each department receives what it needs, when it needs it, without relying on manual carts or forklifts.
To make this work, map out your production flow. What stages need to be connected? What goods move between them? Then assign robots to handle those handoffs.
For example, one robot might be dedicated to moving raw materials from storage to assembly. Another might shuttle finished goods to packaging.
Use priority settings in your robot software to keep urgent items moving first. You can also program schedules based on shift changes or production cycles. That way, your flow stays predictable, and each department has what it needs to keep working.
If you’ve had issues with delays, misrouted items, or inconsistent handoffs, robots can eliminate those weak links. Their consistency ensures that no department is left waiting, which improves output and keeps teams focused on their core work.
Above all, make sure your people know how to interact with the robots. Post clear signage, create designated lanes, and offer training to avoid confusion or slowdowns.
When robots and humans move in harmony, your plant becomes a well-oiled machine—literally and figuratively.
16. 22% of mobile robot adopters replace forklifts with AMRs
Forklifts have been the workhorse of warehouse and plant transport for decades.
But as automation matures, 22% of companies are swapping out forklifts for autonomous mobile robots (AMRs). The shift isn’t just about technology—it’s about safety, efficiency, and long-term cost savings.
Forklifts require licensed operators, constant training, and regular maintenance. They also take up space, pose safety risks, and aren’t always the most efficient tool for repetitive internal movement. AMRs, on the other hand, are smaller, smarter, and safer.
They move predictably, avoid obstacles, and don’t rely on human judgment to navigate tight spaces.
If you’re thinking about replacing forklifts, start by analyzing their current usage. Are they being used for repetitive, point-to-point tasks? Are they often idle or only carrying partial loads? These are signs that AMRs could do the job more efficiently.
Also, consider the layout. Forklifts require wide aisles, which take up valuable floor space. AMRs can operate in narrower paths and even navigate dynamic environments where people are working. This allows for tighter layouts and more productive use of square footage.
Don’t feel like you have to eliminate all forklifts at once. Many businesses adopt a hybrid model. They use forklifts for large or heavy loads and AMRs for smaller, more frequent deliveries. Over time, as confidence grows and needs evolve, you can transition more of the transport work to robots.
Lastly, remember the safety benefits. Forklifts are one of the top causes of warehouse injuries. Replacing even part of your fleet with AMRs can dramatically reduce those risks and create a smoother, safer operation for everyone.
17. 90% of mobile industrial robots are battery-operated with auto-charging capabilities
One of the unsung heroes of AMR performance is battery tech. Today, 90% of mobile robots run on smart battery systems with auto-charging capabilities. That means they know when to head to a charging station, top up, and get back to work—no human involvement required.
This is a huge advantage. It eliminates the downtime and labor needed for manual charging or battery swaps. It also ensures that your fleet runs continuously, even in 24/7 operations. Robots can stagger their charging times so that some are always active while others recharge.
If you’re just starting with mobile robots, be sure to plan your charging strategy carefully. You’ll need to allocate space for charging docks—ideally in locations that are central, out of the way, and easy for the robots to access. Avoid placing them in high-traffic areas or near emergency exits.
Also, talk to your vendor about battery specs. Some batteries support fast charging or partial top-offs, which can help if your workflow is intense. Others prioritize longer life or energy efficiency. Match the battery capabilities to your operational needs.
Track charging data over time. Your fleet management system will usually show you patterns like which robots charge most often, which run closest to empty, or whether traffic is building up at the chargers. Use this data to adjust your task distribution or add extra docks as needed.
The key takeaway: battery management isn’t something you need to handle manually, but it’s something you need to plan for. A smart charging setup ensures your robots are always ready and your operation never misses a beat.
18. 33% increase in throughput capacity observed in robotic-enhanced warehouses
Throughput—the amount of work your facility can handle in a given time—is a direct driver of revenue. That’s why a 33% increase in throughput with mobile robots is such a game-changer. It means your warehouse or plant can do more, faster, without hiring more staff or expanding your space.
So where does this gain come from? It starts with consistency. Robots don’t slow down, don’t take breaks, and don’t get distracted. They keep goods flowing continuously across your operation. That flow eliminates bottlenecks and keeps every department working at full pace.
To get this kind of throughput boost, you need to rethink your workflows around automation. First, focus on reducing idle time. Where are materials sitting around, waiting for the next step? Assign robots to eliminate that delay.
Next, look at timing. Many operations run in bursts—big push in the morning, slowdowns midday, another rush in the afternoon. Robots allow you to smooth out those peaks by distributing work more evenly across the shift.
Also, analyze your process handoffs. Sometimes one area is waiting on another because transport or communication is lagging. Robots can act as the glue between processes, making transitions seamless and fast.
Finally, don’t stop at transport. Look at ways robots can support packing, staging, or even inspection. The more you spread their value across workflows, the more throughput you unlock without hiring more people or adding shifts.
19. 76% of mobile robot systems are integrated with WMS or ERP platforms
The real power of mobile robots comes from their connection to your digital systems. When 76% of robot deployments are tied into a warehouse management system (WMS) or ERP platform, it’s not just about automation—it’s about intelligence.
Integrated robots receive real-time job assignments, report task completion, and help maintain accurate inventory and order status. This turns your warehouse into a responsive, data-driven environment that can adapt on the fly.
If you’re planning a deployment, integration should be part of the plan from day one. Choose a robot system that supports your WMS or ERP out of the box, or that offers robust APIs for custom connections. Don’t settle for “standalone” robots that can’t communicate with your core systems.
Work closely with your IT and operations teams to define what data needs to flow where. Should robots trigger inventory updates? Should your WMS track battery levels or task queues? Map out these details before deployment.
Once live, use integration to enable automation triggers. For example, when stock drops below a threshold, your system can auto-assign a robot to restock. When an order is printed, a robot can begin the pick sequence immediately. These types of workflows reduce lag time and make your operation truly hands-off.
Integration also helps with reporting. When your robot data feeds into your existing dashboards, you can spot trends faster, respond to issues quicker, and make more confident decisions.
20. 88% of adopters report faster cycle times in order processing
Cycle time is the heartbeat of warehouse performance. It’s the total time from receiving an order to getting it out the door. With 88% of robot adopters seeing faster cycle times, it’s clear that automation speeds things up at every step.
How do robots reduce cycle time? They eliminate pauses. In a manual workflow, items often sit waiting for someone to move them to the next stage.
Robots fill those gaps by handling transitions instantly. They also allow processes to run in parallel—for example, while one worker picks items, a robot can already be moving the next batch into place.
If you want to reduce your cycle time, start by mapping your current process from end to end. Identify every place where goods pause. Ask why they’re pausing. Is it because someone’s not available? Because the area is congested? Because a manual handoff is required?
Then look at where robots can intervene. Even small handoffs—like moving a tote from a shelf to a packing station—can add up when repeated hundreds of times a day.
Also, track order aging. Use your data to find out how long different types of orders are sitting at each stage. Use robots to focus on the slowest-moving stages first. That’s where you’ll see the biggest gains.
Lastly, communicate with your team. Faster cycle times often require everyone to work a little differently. Make sure your staff is trained, informed, and ready to adapt. When humans and robots work together seamlessly, your orders fly out the door—and your customers keep coming back.
21. 47% of adopters expand robot use within 1 year of initial deployment
When nearly half of adopters expand their robot fleet within the first year, it tells you something important—once businesses start using mobile robots, they quickly see the value and want more.
It also shows that starting small is smart, as long as you’re ready to scale when the time is right.
So how do you set yourself up for a smooth expansion? It starts with your initial deployment. Choose a platform that’s built to grow with you. That means it should support adding new robots without disrupting your existing workflow.
Look for a provider that offers scalable fleet management, cloud updates, and easy configuration changes.
Your infrastructure should be scalable, too. Install a few extra charging stations up front. Make sure your network can handle more robot traffic. Think about layout flexibility—can you open up new zones or adjust lanes if robot numbers increase?
Monitor your usage from day one. Where are robots making the biggest impact? Where are they struggling? These insights help guide your next phase of deployment.
Maybe you started with transport and now want to add robots for kitting or returns handling. Or maybe you want to replicate a successful workflow in another area of your warehouse or plant.
Also, loop in your team. Employees who’ve worked alongside robots in one zone can help train new teams as you expand. Their firsthand experience will smooth the transition and help avoid common pitfalls.
Growth doesn’t have to be overwhelming. If your foundation is strong, expanding robot use becomes a natural next step—not a risky leap.
22. 19% of mobile robot investments are funded through leasing models
Buying mobile robots outright isn’t the only way to get started. In fact, 19% of companies use leasing or subscription models to fund their investment. This trend is growing fast, especially for businesses that want to stay flexible, preserve cash, or avoid large upfront capital expenses.
Leasing allows you to test the waters without a huge commitment. You can start small, learn what works, and expand gradually. If a certain workflow or robot type doesn’t fit, you can pivot without being stuck with a sunk cost.
To explore leasing, start by identifying your budget and time frame. Do you need short-term capacity to meet seasonal demand? A lease might be perfect. Do you want a long-term automation solution without dipping into capital funds? Consider a multi-year subscription model.
When reviewing leasing agreements, ask the right questions. What’s included in the monthly fee—maintenance, support, software updates? Can you swap robots if your needs change? Is there a path to buy later?
Also, be sure the leasing provider offers strong technical support. Leased robots are still a part of your operation, and if something goes wrong, you need quick help. Some companies even offer Robot-as-a-Service (RaaS) packages that include performance monitoring and on-site training.
Leasing makes robotics accessible to smaller companies and lets you stay nimble in a fast-changing market. It’s not just a financial tool—it’s a strategic one.
23. 60% of adopters utilize robots for just-in-time replenishment
Just-in-time (JIT) replenishment is a powerful strategy. It keeps inventory levels lean, reduces waste, and boosts cash flow. But it only works if your material flow is fast and reliable. That’s where mobile robots come in—and why 60% of adopters use them for JIT tasks.
With JIT, every delay matters. If a workstation runs out of components, production stops. If packing doesn’t have the right boxes or materials, orders get delayed. Robots eliminate those weak links by ensuring items arrive exactly when needed—no sooner, no later.
To enable JIT replenishment, start by identifying critical supply points. These are the stations that can’t afford to run out. Program your robots to monitor those locations and trigger resupply tasks automatically when levels drop below a threshold.
Integration is key. Your inventory or MES system should sync with your robots so that replenishment is based on real-time demand—not manual observation. You can even use weight sensors or RFID tags to automate replenishment triggers.
Another tip—don’t overload your robots with big, infrequent restocks. JIT works best when replenishment happens in small, frequent bursts. This keeps materials fresh, reduces congestion, and ensures your floor stays agile.
Train your staff to work with this flow. JIT works beautifully when everyone understands the rhythm of replenishment and trusts that materials will arrive when needed. Robots help make that trust possible.
24. 38% of mobile robot failures are due to environmental navigation issues
Even the smartest robots can get tripped up by their environment. With 38% of failures tied to navigation problems, it’s clear that a robot is only as effective as the floor it drives on. Obstacles, poor lighting, uneven floors, and even plastic wrap can throw off sensors and cause errors.
The good news? These issues are easy to prevent with a little preparation. Before deployment, do a full site walk-through. Check for floor damage, sudden height changes, cluttered corners, or tight bottlenecks. These areas are where robots struggle most.
Think about traffic patterns. Where do people gather? Where are items frequently dropped or stored temporarily? These high-traffic, unpredictable areas are hotspots for navigation issues. You may need to reroute robots around them or adjust human workflows to keep paths clear.
Another common issue is poor lighting or reflective surfaces. Robots use cameras, LiDAR, or laser scanners to see—and shiny or dark surfaces can throw off readings. Test your lighting and consider surface materials when planning deployment zones.
Once robots are live, monitor failure reports closely. If one area consistently causes errors, make physical changes or reprogram routes. The best systems include adaptive learning, where the robot adjusts based on past performance, but you still need to intervene when patterns emerge.
Don’t treat navigation prep as a one-time task. Conditions change—layouts evolve, pallets move, floors wear down. Regular walk-throughs and clean-up routines will keep your robots running smoothly.
25. 69% of robot-enabled facilities report reduced training time for new workers
Training new employees can be a slow, expensive process. But in 69% of facilities using mobile robots, that process gets easier—and faster. That’s because robots simplify workflows, guide task execution, and reduce the number of steps humans need to remember.
Instead of teaching a new worker an entire process start to finish, you can focus their role on a specific zone or step, with robots handling the transitions.
For example, instead of walking across the warehouse to find a part, the part arrives at their station via robot. That means less orientation time, less room for error, and faster productivity.
To use robots as a training tool, design your workflows with simplicity in mind. Break tasks into focused stages. Let new hires shadow experienced workers in one zone, and rely on robots to handle everything else.
You can also use robot software to support training. Many systems come with visual dashboards or alerts that help guide timing and actions. If a robot is delivering a bin, the screen might show what task to do next.
These prompts act like mini-coaches that reduce dependency on verbal instructions.
Reducing training time doesn’t just save money—it improves morale. New hires feel more confident, less overwhelmed, and more effective from day one. That translates to better retention and a smoother ramp-up during busy periods.
In the long run, robots help create a stable, low-stress environment where people can focus on what they do best—and that’s a win for everyone.
26. 52% of logistics firms adopt mobile robots to meet e-commerce demand
E-commerce has completely transformed logistics. With more orders, smaller batch sizes, and tighter delivery windows, traditional methods just can’t keep up. That’s why 52% of logistics companies now use mobile robots to handle the surge in demand.
Speed and flexibility are key in e-commerce. Orders come in around the clock, and each one might contain a different mix of items, picked from different areas. Mobile robots help by streamlining movement, reducing picking times, and keeping inventory flowing to where it’s needed.
To meet e-commerce demands, focus on your picking strategy. Mobile robots can follow pickers, deliver picked items to packing stations, or even guide workers through the most efficient pick path. The goal is to reduce wasted steps and shorten the time from order to shipment.
Think about high-volume zones, too. During peak periods like holidays, certain SKUs fly off the shelves. Assign robots to restock those fast-moving items continuously so pickers don’t get slowed down.
Consider integrating your order management system directly with your robot platform. This allows you to prioritize urgent orders automatically, batch similar ones together, or adjust robot workflows on the fly.
Most importantly, stay flexible. E-commerce trends shift quickly. A promotion can spike demand for a single product overnight. A robot-enabled operation can adapt quickly—rerouting, reassigning, and rebalancing tasks in real time.
In a logistics world where speed wins, mobile robots give you the agility to meet demand without burning out your workforce or expanding your building.
27. 64% of mobile robots operate collaboratively with human workers (cobots)
The best robots don’t replace people—they work with them. In fact, 64% of mobile robots in warehouses and plants are collaborative robots (cobots). These machines are designed to move safely among humans, assist in daily tasks, and make everyone’s job easier.
Cobots are different from traditional robots. They’re smaller, slower-moving, and built with sensors to avoid collisions. You don’t need to cage them off or install major safety barriers. That makes them perfect for dynamic environments where people are constantly moving.
If you’re adding cobots to your team, success starts with culture. Make sure your staff sees them as teammates, not threats. Hold hands-on training. Show how the robots work, what they do, and how they help reduce physical strain and repetitive tasks.
Use cobots for support roles. Let them handle the heavy lifting, long-distance walking, or constant back-and-forth trips. This frees up your team to focus on things that require judgment, precision, or flexibility—areas where humans shine.
Be intentional about how cobots interact with humans. Place screens or signals on the robots so workers know where they’re headed or what they’re carrying. Design workflows where robots arrive right when they’re needed, minimizing wait time or confusion.
The more your team trusts and understands the robots, the smoother your operations will run. Over time, workers will even start making suggestions for how to improve robot usage—turning your operation into a true human-robot partnership.
28. 80% of adopters plan to invest in AI-enhanced robot systems by 2026
The future of mobile robots isn’t just movement—it’s intelligence. With 80% of adopters planning to invest in AI-enhanced robots by 2026, the industry is shifting toward machines that don’t just follow instructions, but make decisions.
AI-powered robots can adjust routes in real-time, predict congestion, optimize pick sequences, or even anticipate inventory needs. This allows for smoother operations, faster recovery from disruptions, and smarter use of resources.
To prepare for this shift, start looking at your data. AI thrives on information. Your robot system should be capturing task history, travel times, delays, and errors. If it’s not, upgrade your software or choose a provider that prioritizes data integration.
Once you have the data, explore small AI-driven upgrades. For example, try dynamic routing—where robots adjust their path based on floor traffic or task priority. Or use AI to analyze battery usage and optimize charging schedules.
Also, talk to your vendor about their AI roadmap. Are they developing predictive task allocation? Can their system learn from patterns? Knowing what’s coming can help you align your investment and avoid being stuck with outdated tools.
Finally, educate your team. AI-enhanced robots may require different oversight or interaction. Train your supervisors to read robot analytics, adjust parameters, or respond to system recommendations.
AI is the next layer of performance. With smarter decisions and faster reactions, it takes mobile robotics from automation to optimization.
29. 30% reduction in product handling errors reported post-robot deployment
Every time a product is handled, there’s a risk—wrong item picked, box dropped, label missed. These errors add up fast in terms of cost, rework, and customer frustration. That’s why a 30% drop in handling errors after robot deployment is a big win.
Robots reduce handling errors by standardizing processes. They follow the same path, carry loads evenly, and don’t forget steps. When they’re used to transport items between stations, they eliminate the handoff points where mistakes often happen.
To reduce your own handling errors, start by identifying where they happen most. Is it during picking? Packing? Putaway? Assign robots to those transitions, ensuring the process is consistent and tracked.
Use sensors, barcode scanners, or RFID systems to double-check that the right items are moving to the right place. Many robot systems come with built-in validation tools that confirm a bin’s identity before it’s moved.
Another tip: automate your quality checks. You can route picked items past a scanning station or camera that flags mislabeled or incomplete orders. Robots can then redirect those items to rework zones automatically.
Consistency is the biggest driver of accuracy. When robots handle the transport, and humans handle the judgment, you reduce both workload and error rate. That creates a smoother, more reliable operation from end to end.
30. 58% of mobile industrial robot deployments are in North America and Europe
The adoption of mobile industrial robots is growing globally, but North America and Europe are leading the charge, accounting for 58% of total deployments. This reflects both the maturity of these markets and the high demand for labor-saving, efficiency-boosting solutions.
If you’re in one of these regions, you’re in a prime position to benefit. There’s a growing ecosystem of providers, integrators, consultants, and success stories to learn from. Local support and expertise are easier to find, and you’ll often see industry peers using robots in similar ways.
Use this to your advantage. Visit trade shows, tour robotic-enabled warehouses, and join automation networks. Learning from others will help you avoid mistakes and fast-track your implementation.
Also, keep an eye on regional trends. In North America, the focus is often on scalability and high-volume fulfillment. In Europe, efficiency, footprint optimization, and energy use are bigger concerns due to space and regulatory pressures.
Tailor your strategy accordingly. If you’re in a dense urban area, choose smaller robots that handle narrow paths. If your energy costs are high, look for efficient battery systems or solar-assisted charging options.
Being part of a leading region also means facing rising expectations. Customers, partners, and even investors expect modern, optimized operations. Mobile robots are no longer a novelty—they’re becoming the standard.
wrapping it up
Mobile industrial robots are reshaping the way warehouses and plants operate. From faster fulfillment and reduced labor costs to improved safety and scalability, the stats speak for themselves. But stats alone won’t transform your business—action will.
