The integration of robotics into warehouse operations has been lauded as a significant advancement in improving worker safety. However, recent research suggests that while automation may reduce certain types of injuries, it does not necessarily make warehouse environments safer overall.
A study titled “Lucy and the Chocolate Factory: Warehouse Robotics and Worker Safety” by Brad N. Greenwood, Gordon Burtch of Boston University, and Kiron Ravindran of IE University, examines the impact of robotics on worker safety in fulfillment centers. The researchers found that robotic fulfillment centers experienced a 40% decrease in severe injuries but a 77% increase in non-severe injuries compared to traditional centers.
Burtch, G., Greenwood, B., & Ravindran, K. (2025). Lucy and the Chocolate Factory: Warehouse Robotics and Worker Safety. ILR Review, 78(4), 587–613. https://doi.org/10.1177/00197939251333754
Brad N. Greenwood, Dean’s Distinguished Professor at the Costello College of Business at George Mason University stated,
“Companies have bottom-line reasons to take this issue seriously. Beyond simple issues of liability, there is a cost to the firm of workers being unable to perform their duties'”.
Severe injuries, such as broken bones and traumatic falls, decreased due to robots handling physically demanding tasks like heavy lifting and long-distance walking. However, non-severe injuries, including sprains, strains, and repetitive motion problems, increased significantly. These injuries often lead to reassignment or light-duty work but not necessarily to missed workdays.
The study also analyzed thousands of online posts from Amazon warehouse workers, revealing a discrepancy in worker opinion based on whether their fulfillment center was roboticized. Workers in robotic centers reported a less physically exhausting experience but also noted higher performance expectations and a more repetitive work routine, leading to burnout and decreased job satisfaction.
These findings highlight the complexity of automation’s impact on worker safety. While robots can mitigate certain physical risks, they may introduce new hazards related to task monotony and increased performance pressure. This shift in risk underscores the need for careful job design, task rotation, and realistic performance goals to ensure that automation leads to genuine improvements in worker safety and well-being.
In conclusion, the adoption of robotics in warehouses does not inherently make work safer. Without thoughtful integration and consideration of human factors, automation can merely reshuffle risks rather than eliminate them. As the industry continues to evolve, it is crucial to balance technological advancements with a commitment to worker health and safety.
Adrian graduated with a Masters Degree (1st Class Honours) in Chemical Engineering from Chester University along with Harris. His master’s research aimed to develop a standardadised clean water oxygenation transfer procedure to test bubble diffusers that are currently used in the wastewater industry commercial market. He has also undergone placments in both US and China primarely focused within the R&D department and is an associate member of the Institute of Chemical Engineers (IChemE).
