Global investment in warehouse automation is surging and transforming distribution centers (DCs) into highly engineered, technology-driven operations. The global warehouse automation market continues to expand. What used to be a competitive edge has become table stakes for companies facing rising demand, changing customer expectations, and pressure for faster fulfillment.

As warehouse automation spending triples over the next five years, the technology must prove its value. Companies are realizing the investment only pays off if systems keep delivering over time. The real challenge is keeping those systems running at peak performance as demand and complexity grow.

Put simply, you can’t just set and forget automation. The systems must continue delivering results, improving efficiency, increasing throughput, and adapting to constant change. Without ongoing attention to maintenance and upgrades, even the most advanced technology may fall short of expectations.

That’s where Lifecycle Solutions & Services helps keep automation performing at its designed output. And it’s not just about fixing what’s broken. It’s about monitoring performance, extending asset life, upgrading as technology evolves, and ensuring hardware, software, and people work as a synchronized system.

For any automation installation, go-live is a milestone, but it’s not the finish line. For example:

• Motors, belts, and batteries degrade
• Buffers and sort points need readjusting
• Interfaces fall behind on updates

Left unchecked, these and other issues can quietly chip away at productivity, drive up costs, and cut into revenue and customer trust. Customer experiences are shared instantly online — accurate fulfillment protects brand reputation.

Consumer tolerance for delayed or problem orders continues to decrease. In fact, many will switch sellers after just a few late or incorrect orders, and most place high value on items arriving within the promised arrival windows. On-time delivery is now a top priority according to a recent report from McKinsey & Co., which says half of all consumers use order tracking platforms to keep tabs on their orders.

With customers and business partners watching closely, companies can’t afford missteps. They need strong Lifecycle Solutions & Services to keep the automation performing as designed and a trusted provider that treats automation as a living asset — monitoring performance, scheduling preventive maintenance, and using analytics to predict failures before they happen. Just as routine service extends the life of a car, Lifecycle Solutions & Services keeps automation running, adapts it to changing business needs, and protects ROI by preventing costly downtime.

The real return on automation comes from consistent long-term uptime, not from what the system does on day one. A new pallet shuttle solution may initially run perfectly, for example, but without targeted upkeep, small wear points can cascade into unplanned downtime. These outages can add up for DCs and warehouses where regular maintenance:

• Extends asset life and avoids costly replacements through regular upkeep and targeted repairs. It also provides powerful obsolescence management. Components, controls, and software eventually age out. A clear roadmap for upgrades and compatibility keeps automation running reliably and extends system life by preparing operations for mechanical and technology shifts.
• Keeps systems current with planned upgrades, retrofits, and evolving technology standards. It also helps maintain performance and throughput, even during spikes in order volume.
• Simplifies system maintenance. With automated equipment and software proliferating at a rapid pace, companies risk higher maintenance response times by taking a piecemeal approach. A trusted partner like Dematic unifies and maintains systems across both OEM and third-party equipment.
• Boosts efficiency and prevents bottlenecks by catching small issues before they disrupt workflows. Regular maintenance provides data, analytics, and remote monitoring to detect and resolve problems faster.
• Helps your company scale. Lifecycle Solutions & Services support system customization, expansion, and integration of new technologies as business needs evolve. This ensures automation investments scale to meet demand.

Preventive maintenance is one of the most cost-effective ways to protect — and get the most out of — automation investments. Waiting until something breaks almost always costs more, whether because of emergency repairs, replacement parts, or lost productivity. A proactive approach extends asset life, reduces errors, and keeps operations running smoothly, turning maintenance into a measurable source of savings.

And every hour of uptime accelerates payback in an automated environment. Proactive maintenance is a direct driver of ROI — predictive analytics, IoT sensors, and remote monitoring help catch issues before they disrupt operations. Lifecycle Solutions & Services ensures automation delivers at design capacity and continues paying for itself year after year.

Lifecycle Solutions & Services also plays a critical role in sustainability that goes beyond simply installing energy-efficient equipment. By extending asset life, reducing energy use, and minimizing waste, it helps operations meet ESG goals while avoiding disruptions to workers and consumers alike. Safety-focused tools add another layer of protection. When these pieces come together, maintenance stops being a cost center and becomes a driver of ROI and operational resilience.

It’s common for organizations to focus on fixing issues as they happen versus anticipating them. This approach may suffice for basic equipment, but it can get costly and time consuming in an automated facility where even a single issue can bring down an operation, and lead to delayed shipments, logistics headaches, and unhappy customers.

The good news is even companies that don’t have in-house automation experts can efficiently maintain and support their automation investments with Lifecycle Solutions & Services providers. They get on-site experts, 24/7 remote support, parts, digital tools, training, and IT services that help people and processes stay in sync. Planned upgrades ensure automation evolves with their business, sustaining uptime and ROI long after go-live.

Long-term success with warehouse automation isn’t a given, but Lifecycle Solutions & Services is essential for automation to deliver success beyond day one. It’s not about waiting for something to break, it’s about keeping systems current, dependable, and ready for whatever comes next. With expert training, planned upgrades, cross-platform support, and clear roadmaps for aging equipment, Lifecycle Solutions & Services from an industry expert like Dematic provides companies with confidence in their automation.

Lifecycle Solutions & Services are not extras to add on after installation. They’re central to whether automation delivers value over time. Any system can perform on day one, but the real test comes during year five, 10, and beyond.

Here are some tips to keep in mind as you go through the partner evaluation process: 

• Focus on resilience, not the technology itself. Pick a partner with a proven record for the long haul.
• Look beyond the hardware. Technology is only part of the equation. Strong software, controls and support is what keeps it performing.
• Evaluate the full Lifecycle Solutions & Services package. Check for clear service level agreements (SLAs), staff expertise, and access to OEM and third-party spare parts.
• Prioritize ongoing integration. Ensure support structures keep people, processes, and systems working together over time.
• Integrate your service concept early. Plan and build in service requirements during the site’s planning phase — adding them later is more costly and time-consuming.
• Plan for year five and beyond. Select a provider capable of keeping your automation reliable, efficient, and sustainable for the full lifecycle of the system.

Ultimately, warehouse automation is only as strong as the service that sustains it, which is why companies can’t afford to treat support as an afterthought. Technology delivers lasting value when it’s consistently maintained and updated. Asking the right questions about service commitments, integration, and long-term reliability upfront will ensure performance over time and protect your investment well into the future.