Warehouse Robots Are Here. But Do They Hurt Or Help Worker Safety?

Amazon is now testing a new robot in its warehouses: a humanoid bipedal robot designed to work collaboratively with humans. Named Digit and created by Agility Robotics, the robot looks and moves like a human and can take over dangerous or repetitive tasks to improve both productivity and worker safety. Increasingly, robotic technologies are being installed across U.S. industries, and they’re becoming ever-more collaborative and versatile in their designs. In fact, by 2025, it’s estimated four million robots will work in over 50,000 facilities across the country.  

Yet, although robotic technologies are often touted as a way of improving warehouse safety, this issue isn’t so clear cut. From collisions to malfunctions, “[robots] introduce new workplace hazards for those who work with, and alongside them,” warns OSHA spokesperson Kimberly Darby. So, it’s important warehouse operators and workers aren’t fooled into a false sense of security as robots increasingly become their new co-workers. By preparing for growing levels of warehouse automation and understanding the risks involved, warehouse operators and workers will be better prepared to work alongside robots and avoid accident and injury.  

Are robots actually improving safety so far? 

According to Amazon, robotics have already made positive improvements to safety in their warehouses. In 2022, the accident and injury rate at Amazon warehouses with robotics tech installed was 15% lower compared to regular warehouses, while lost time incident rates were also 18% lower, Amazon’s own data shows. Although the accuracy of these statistics has been contested. It’s also worth noting the Bureau of Labor Statistics hasn’t yet published data on the impact of robots on injuries among human workers.

“Robotics by design makes operations safer and easier for our employees,” says Maureen Lynch Vogel, an Amazon spokesperson. For instance, Amazon’s Proteus robot has been designed with “advanced safety, perception and navigation technology” that allows it to work safely around human workers. Proteus beams a green light while it works, and if a human is detected to step into its path, the robot immediately stops in its tracks.

There’s also Sequoia: a robot that moves, lifts, and sorts containers. Again, Amazon says Sequoia improves warehouse safety. “The system helps take the strain away from employees bending and stretching”, explains Amazon Robotics’ chief technologist Tye Brady. So far in 2024, Amazon has installed a total 750,000 robots in fulfillment centers and warehouses, up from 350,000 in 2021. 

Human safety concerns remain

Yet, despite Amazon’s claims of safety improvement, workers’ watch dogs also warn that robotics tech is actually making the job more dangerous for human workers. As robots can do the job of moving objects around the warehouse, for instance, human workers largely stay in one place throughout their shift performing repetitive tasks as a result. Additionally, Amazon’s robots are super productive, which is theoretically a good thing. Except human workers are now expected to keep pace with them. Some Amazon pickers say they’re now expected to move 400 items an hour, up from 100. 

Although the Occupational Safety and Health Administration doesn’t yet have formal standards in place to enforce the responsible use of industrial robots in the workplace, they are, however, currently monitoring key safety issues associated with advanced manufacturing technologies (including, autonomous mobile robots, as well as automated guided vehicles and autonomous forklifts). 

Self-driving forklifts promise to improve safety 

As for self-driving forklifts, they may actually be safer for human workers — even if it’s just because they eliminate the need for human drivers as it’s the driver who’s usually injured in these types of accidents. “At this point there aren’t any industry-wide statistics that prove AMRs [autonomous mobile robots] are safer than manual forklifts,” notes Michael Bearman, chief administrative officer at Vecna Robotics. “That said, we know that our AMRs are guaranteed to be safer.” According to Bearman, autonomous mobile robots feature reliable safety protocols and software-based monitoring systems that assure safety.

Moreover, features have also been developed to successfully improve safety in robotics technology. For instance, AI has been integrated into collaborative robotics, so robots can now better detect objects and humans, and accurately distinguish between the two. Thanks to the improvements to health, safety, and productivity made by this type of cutting-edge feature, it therefore isn’t surprising that 73% of manufacturing businesses consider automation to be crucial to industry progression.

Creating a safer future means planning for the unexpected

Paving the way for a safer workplace of the future should mean preparing for the unpredictability that’s inherent within robotics. “While robots are designed for safety—and for repetition— it’s variability which can lead to accidents”, explains Bearman. “Warehouses need to plan for the unexpected” in order to keep accident and injury rates low in increasingly automated environments. 

At a bare minimum, comprehensive safety training should be implemented to teach warehouse operators about the risks that come with working alongside robots. In particular, operators need to be mindful of issues like bad flooring, blind corners, low ceilings, and routes that may be used simultaneously by human workers. The importance of proper signage for safety also shouldn’t be underestimated.  

Like it or not, robots are here to stay. “Workers need to be made aware of the unique dangers associated with working around or with industrial robots”, comments Darby. By preparing for increasing levels of warehouse automation and understanding the risks involved, warehouse operators and workers will be better prepared to work smoothly alongside robots and keep accident rates down.