The Automation Aftershock: Why Preventative Maintenance is Critical to Long-Term ROI
Executive Summary
The COVID-19 pandemic fueled a massive surge in e-commerce, pushing many companies to rapidly invest in warehouse automation. From robotic picking arms to fast-moving sortation systems, technology was deployed at record speed to keep up with demand. But while capital investments soared, maintenance strategies often lagged behind.
Now, several years later, the gap is catching up to operations. Unplanned downtime, costly repairs, and declining system performance are all becoming more common.
This white paper explains why preventative and predictive maintenance are essential to protecting your automation investment. We’ll show how data-driven maintenance reduces risk, improves uptime, and helps ensure your systems keep delivering value. We’ll also explain how our team can support your equipment with flexible service models tailored to your operation.
What Happened After the Pandemic Automation Boom
Between 2020 and 2022, companies rushed to install:
Conveyor and sortation systems
Autonomous mobile robots (AMRs)
Robotic palletizing and depalletizing systems
Automated storage and retrieval systems (ASRS)
These technologies helped meet surging demand, but in many cases, maintenance plans were an afterthought. Today, the consequences are showing up in the form of:
Increased repair costs
Missed SLAs due to unexpected breakdowns
Deferred maintenance backlogs
Safety issues tied to mechanical failures
The systems worked well—until they didn’t.
Why Preventative Maintenance Matters
Preventative maintenance involves regular inspections, adjustments, lubrication, and part replacements before failures occur. It’s a proactive approach that keeps equipment running reliably and efficiently.
Benefits of a Well-Run PM Program
Reduces unplanned downtime
Extends the life of your equipment
Improves safety by ensuring all guards and sensors are functional
Keeps throughput high by avoiding performance issues
Protects the return on your automation investment
A strong PM program can more than pay for itself by minimizing emergency repairs and maintaining productivity.
From Preventative to Predictive Maintenance
Modern automation systems are equipped with sensors that track performance in real time. Predictive maintenance uses this data to detect early signs of failure—so you can take action before the issue becomes serious.
Key Predictive Indicators
| Sensor Data | What It Reveals |
|---|---|
| Motor temperature | Warning signs of overheating or friction |
| Amp draw | Indicates strain, misalignment, or motor wear |
| Vibration | Detects imbalance or bearing wear |
| Runtime hours | Helps schedule time-based maintenance |
| Air pressure or vacuum | Important for pneumatic tools and robotic end effectors |
This data can be monitored through a CMMS or maintenance software platform to support timely, informed decisions.
How We Help Keep Your Systems Running
As a trusted integrator and service partner, we offer maintenance support that aligns with your goals, budget, and in-house resources.
Option 1: Embedded Maintenance Technicians
We provide full-time, on-site maintenance experts who:
Complete daily PM tasks
Troubleshoot and repair systems in real time
Follow proper lockout/tagout (LOTO) procedures
Support continuous improvement with data feedback
This approach is ideal for high-volume sites or critical automation environments that run multiple shifts.
Option 2: Quarterly PM Visits
For smaller sites or those with internal technicians, our team can perform quarterly maintenance visits that include:
Full equipment inspections
Cleaning, lubrication, and calibration
Replacement of consumables like belts or rollers
Documentation of findings and recommendations
On-site training for your team on basic maintenance and safe practices
This model offers expert oversight without requiring full-time staff.
Safety Is Always the Priority
Every service visit follows OSHA-compliant lockout/tagout procedures. Our technicians are trained in electrical and mechanical safety, as well as:
Machine guarding standards
Fall protection
Arc flash safety
Confined space protocols, where applicable
A proper PM program protects more than just machines—it protects the people who work with them.
The Bottom Line: PM Saves Time, Money, and Stress
| Without PM | With PM |
|---|---|
| Equipment failures at the worst time | Fewer surprises and better uptime |
| High emergency repair costs | Predictable, lower-cost maintenance |
| Line stoppages and missed deadlines | Consistent throughput |
| Increased safety risks | Safer working environment |
| Shorter equipment life | Extended system performance and ROI |
Preventative maintenance is one of the smartest ways to protect your automation investment.
Let’s Build a Plan That Works for You
Whether you just installed automation or you’re dealing with aging systems from the pandemic rush, we can help. Our team can assess your needs and design a maintenance approach that fits your site.
Contact us today for a free evaluation.