AI becomes standard across global warehouses: Study

Warehouses at the heart of global supply chains are rapidly transforming into highly intelligent, data-driven operations, according to a new joint study by intralogistics specialist Mecalux and the MIT Intelligent Logistics Systems (ILS) Lab at MIT’s Center for Transportation and Logistics.

Based on insights from more than 2,000 warehousing and supply-chain professionals across 21 countries, the research finds that artificial intelligence is no longer confined to pilot projects. Instead, it has become a foundational element of modern warehouse operations. Nearly 60 per cent of warehouses now have AI deeply embedded in their processes, while more than 90 per cent use some form of AI or advanced automation.

Larger organizations with complex, multi-site logistics networks are leading this shift, with over half of respondents reporting advanced or fully automated maturity levels. AI is increasingly woven into daily operations, supporting functions such as order picking, inventory optimization, predictive maintenance, workforce planning and safety oversight.

The study also highlights faster-than-expected returns on AI investments. Most companies allocate between 11 and 30 per cent of their warehouse technology budgets to AI and machine-learning initiatives, with payback typically achieved within two to three years. These gains are driven by tangible improvements in throughput, inventory accuracy, labour productivity and error reduction, signalling a clear shift from experimentation to long-term capability building.

Importantly, the findings push back against concerns that automation will displace workers. Instead, AI adoption is associated with higher productivity and improved job satisfaction. More than three-quarters of respondents reported positive workforce outcomes following AI implementation, and over half said their warehouse workforce had expanded. New roles are emerging in areas such as AI engineering, automation, data science and process improvement.

Looking ahead, momentum is set to accelerate. Almost all surveyed companies plan to expand their AI deployments over the next two to three years. About 87 per cent expect to raise AI budgets, and 92 per cent are either launching or planning new AI initiatives.

The next phase of adoption is expected to focus on decision-making technologies, particularly generative AI. Respondents identified generative AI as the most valuable emerging tool, with applications ranging from automated documentation and warehouse-layout design to process optimization and software development for automation systems.

As generative capabilities mature, warehouses are expected to move beyond prediction toward automated, real-time decision-making. The study concludes that AI’s greatest impact lies in making operations smoother, faster and more resilient—cementing intelligent automation as a core pillar of future warehouse performance.