Effective Change Management: The Key to Automation Adoption

Sheila Dooley | 26 February 2025

Automation in material handling is often celebrated for its ability to increase speed, accuracy and efficiency while reducing operational costs. However, one crucial factor determining the success of automation projects is often overlooked: employee adoption. Implementing new systems isn't just about integrating technology; it's about ensuring the people impacted by these changes understand, accept and embrace them. When executed well, change management bridges this gap, driving both operational success and a positive work culture.

Addressing Employee Concerns in Material Handling Automation

Employees may have legitimate concerns when a company introduces automation. Some worry about job security, others about learning complex new systems and many are apprehensive about losing their "tribal knowledge"—the expertise they’ve built over years of hands-on work.

To address these concerns, leaders must engage employees early in the process. Providing clear, honest communication about the benefits—such as improved safety, reduced physical strain and fewer repetitive tasks—can help alleviate opposition. Employees should not only understand the what and why of the change but also how it directly affects them. Encouraging feedback early allows leadership to address concerns, make necessary adjustments and set the stage for smoother adoption.

Effective Communication Strategies for Automation Adoption

It’s key for leadership to deliver a direct, simple and transparent message about automation implementation. A vague or inconsistent message can lead to confusion, resistance, or even misinformation spreading among employees. Successful change management requires understanding the current processes, identifying gaps and ensuring employees have a clear vision of the future. It’s important for company leadership to also carefully consider all the different recipients and their roles within the context of the change. Communication should be relevant and relatable to each individual specifically and not speak to a general change in the company.

The most effective change initiatives use multiple communication channels—town halls, signage, team meetings and one-on-one discussions—to reinforce the message. Consistency is key; employees need to hear the same message multiple times in various ways.

Employee Engagement and Ownership When Transitioning to Automation

Employees involved in the change process are more likely to embrace it. Encouraging participation through open discussions, Q&A sessions and feedback mechanisms can generate curiosity and engagement. Employees should feel like active contributors rather than passive recipients of change.

One effective strategy is to create a clear narrative around the change. Instead of simply presenting facts and figures, tell a compelling story about how automation will enhance efficiency, create new opportunities and improve daily operations. This approach helps employees connect with the vision, making the transition feel less like an imposition and more like an evolution.

Automation Training: The Cornerstone of Change Management

Training is perhaps the most tangible aspect of change management. It teaches employees how to use new technology and eases anxieties related to process, role and cultural shifts.

A successful training strategy should:

• Go beyond technical instruction to include process adaptation and problem-solving.
• Provide hands-on opportunities for employees to practice in real or simulated environments.
• Allow early adopters and advocates to support their peers through mentorship or train-the-trainer models.
• Offer continued learning opportunities post-go-live to reinforce skills and refine processes.

It’s far easier to sustain long-term success with a well-trained workforce than to struggle with adoption after implementation.

Change Management Case Studies: Successful Automation Adoption

While change management principles apply broadly, real-world examples illustrate their impact in action. The following case studies showcase how thoughtful communication, engagement and training strategies led to successful automation adoption.

Case Study 1: Brownfield Site Transformation
A company transitioning from manual operations to a new WMS (warehouse management system), RF scanners and conveyor routing recognized the importance of employee involvement from the start.

Months before implementation, leadership communicated the upcoming changes across all levels of the organization. They used posters throughout the facility, set up anonymous question boxes and provided regular updates to maintain transparency.

During training, they discovered unexpected reactions—some employees who were expected to resist the change were actually the most eager to learn and help others. Meanwhile, some chosen trainers were less adaptable than anticipated. The company quickly adjusted, reassigning training roles to those most engaged in the change.

At go-live, they provided color-coded shirts to designate support personnel, making it easy for employees to find help when needed. As a result, adoption was rapid and resistance was minimal.

Case Study 2: Greenfield Site with the Existing Workforce
A company moving to a new facility just minutes away faced another complexity: employees had to adapt to a new environment and entirely new automation systems.

Leadership prioritized early and frequent communication, involving key employees in training sessions long before the transition. They conducted on-site volume testing and mock go-lives, helping employees familiarize themselves with new processes and identifying any gaps in training.

Employees felt confident and prepared by go-live, leading to a smooth transition with minimal disruptions. The company's investment in upfront communication and employee involvement paid off with high adoption rates and operational efficiency from day one.

Long-Term Success: Sustaining Change in Automated Operations

Change management doesn’t end at activation. A company’s ability to sustain and continuously improve automation adoption depends on ongoing feedback, performance analysis and continuous learning. Leaders should:

• Regularly evaluate what worked well and what needs improvement.
• Use employee feedback to refine processes and training.
• Encourage a culture where change is expected, embraced and celebrated.

By keeping employees engaged beyond the initial implementation, companies can cultivate an adaptable workforce ready for future innovations.

Optimizing Material Handling Automation Success: Next Steps

Successful material handling automation is more than installing technology—it also successfully guides your people through the change. Partnering with an experienced material handling automation integrator can make all the difference in ensuring smooth implementation and long-term success. When done correctly, change management accelerates adoption, improves employee morale and ensures long-term operational success.

The key lies in proactive communication, engaging employees early, providing thorough training and fostering a culture where change is not feared but welcomed. Bastian Solutions brings deep expertise in managing automation implementations and supporting clients through an ongoing partnership. Investing in these efforts lays the foundation for a resilient and forward-thinking workforce.

Contact a Bastian Solutions engineer today to discuss your project and explore how we can help you navigate automation with confidence.

Author: Sheila Dooley