As Black Friday approaches, a new study from Mecalux and the MIT Intelligent Logistics Systems Lab shows that warehouse automation and AI are not replacing workers. They are helping people do their jobs better and opening new roles across the industry.

What’s Related

The survey, based on answers from more than 2,000 logistics leaders in 21 countries, found that more than 90% of warehouses now use some form of AI or automation. Over half say they have reached advanced or fully automated stages, especially larger companies with several warehouse locations.

AI is becoming part of everyday work on the warehouse floor. It supports order picking, inventory management, labor planning, safety checks, and equipment maintenance. “The data shows that intelligent warehouses outperform not only in volume and accuracy, but in adaptability,” said Javier Carrillo, CEO of Mecalux. He added that companies using AI are “more resilient, more predictable, and better positioned to navigate volatility” during peak season.

Budgets on the rise

AI investments are also paying off faster than many expected. Most companies now put between 11 percent and 30 percent of their tech budgets into AI. The typical payback period is 2 to 3 years. The study ties those returns to greater inventory accuracy, faster throughput, fewer mistakes, and better labor use. Many companies are moving from test projects to long-term planning.

Challenges remain. Leaders pointed to system integration issues, technical expertise, data quality, and upfront cost as the hardest parts of scaling AI across the operation. “The hard part now is the last mile. Integrating people, data, and analytics seamlessly into existing systems,” said Dr. Matthias Winkenbach, Director of the MIT ILS Lab.

AI and jobs

One of the biggest surprises in the study is the impact on hiring. More than half of the respondents said AI led to an increase in headcount. More than three out of four reported higher employee satisfaction and productivity after adopting the tools. New roles are now typical in warehouses such as AI engineers, data specialists, and automation technicians.

Generative AI is the next step

The study also found that 92 percent of companies are investing in AI or planning new projects. Eighty-seven percent expect their AI budgets to go up over the next three years. The next big step will be decision tools powered by generative AI. Respondents called it the most valuable technology in today’s warehouses.

“Traditional machine learning is great at predicting problems, but generative AI actually helps you engineer the solution,” said Dr. Winkenbach. He pointed to examples such as documentation, layout planning, and code generation for warehouse systems.

As Black Friday orders ramp up, warehouses are becoming smarter instead of just more automated. The study suggests that AI is helping people work faster and with fewer disruptions while expanding human roles across the supply chain.