The future of intralogistics: will forklift trucks be replaced by AI robots?
A reality check between Industry 4.0 hype and Logistics 5.0
Digital change is accelerating. Algorithms, artificial intelligence (AI) and autonomous systems seem to be outsourcing the logistical skills of entire forklift truck driver teams – firmly anchored in the belief that technology can do everything more efficiently, faster and cheaper. The focus of Industry 4.0 is clearly on automation, networking and maximising profits through digitalisation.
But while we are talking about fully automated “dark warehouses” in which armies of robots take command, a more nuanced picture is emerging. Experts are already talking about Logistics 5.0, where people are once again taking centre stage – supported by resilience, sustainability and ethical work design.
The key question for retailers, freight forwarders and logistics managers is therefore: Do we have to scrap our forklift trucks and retire the workforce? Will this inevitably lead to total automation?
The reality of automation: limits and risks
Digital warehouses, controlled by AI, are a reality today. However, fully automated systems are only efficient as long as the parameters remain static. The Achilles heel of full automation is its rigidity:
According to studies such as those by Interact Analysis, the market for mobile robotics is growing rapidly, but the hurdles to return on investment (ROI) remain high. Robots need standardisation. The more differentiated the products and the more variable the packaging units, the more difficult it is for the robot compared to a flexible human on a forklift truck.
The players: Who will be travelling through the warehouse of tomorrow?
It’s no longer just the classic forklift truck. The ecosystem has diversified:
Until a few years ago, AGVs were considered a niche product. Today, AI-supported AMRs are available for many applications. Does this mean the end of the forklift truck? No. It just means the end of the dumb forklift truck.
The renaissance of the forklift truck
The forklift truck is not dying out, it is evolving. Manually operated industrial trucks remain indispensable, particularly in small and medium-sized enterprises (SMEs) and parts of the wholesale trade. Sales figures for warehouse technology continue to grow globally, often in parallel with automation.
Why the forklift truck stays:
Conclusion: symbiosis instead of displacement
Forklift trucks are and will remain a key component in intralogistics. We are moving towards a hybrid future. Robots will take over the monotonous, simple routes (horizontal transport), while qualified forklift drivers with high-tech equipment will take over the complex tasks (vertical transport, special loads).
The answer to the question of the future is therefore not “man or machine”, but “man with machine”. If you want to remain competitive, don’t dispose of your forklift trucks, but integrate them into an intelligent, digital overall system.
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