Robots working alongside humans in warehouses have been praised for reducing dangerous tasks, but new evidence reveals a significant downside. According to recent research examining Amazon fulfillment centers, warehouse robotics are associated with fewer severe injuries but lead to a sharp rise in less serious ones.
The study, conducted by researchers Gordon Burtch from Boston University, Brad N. Greenwood from George Mason University, and Kiron Ravindran from IE University, analyzed data from more than 140 Amazon warehouses across the United States between 2016 and 2020. Their findings, detailed in a working paper published on the Social Science Research Network (SSRN), offer important insights for businesses, workers, and policymakers alike.
Severe Injuries Drop by 40% with Robots
At first glance, robotics in warehouses appear to fulfill their safety promise. The researchers found that severe injuries—such as those requiring days off work—fell by approximately 40 percent at robot-equipped fulfillment centers compared to traditional ones. Robots, which can perform tasks involving heavy lifting and repetitive movements, likely reduce exposure to hazardous situations for human employees.
But Minor Injuries Spike by 77%
Yet the same automation that protects workers from severe harm appears to introduce new risks. Non-severe injuries—mostly repetitive strain injuries like sprains, strains, and minor ergonomic conditions—increased by roughly 77 percent in facilities utilizing robots.
This dramatic rise in minor injuries is largely due to the faster pace of work set by robotic automation. Because robots work tirelessly and swiftly, human workers often face higher productivity demands to keep up. This increased speed and reduced task variety place greater stress on workers, leading directly to more repetitive-motion injuries.
Injury Rates Jump During Busy Periods
The researchers found that the injury problem intensifies during high-pressure times, such as Black Friday and Amazon Prime Day, when warehouse activity significantly increases. During these periods, non-severe injury rates at robotic warehouses rose notably, emphasizing the link between high workloads driven by automation and increased injury risk.
Workers Report Increased Pressure and Monotony
Insights from worker forums such as Reddit align with the research findings. Employees frequently describe robotic fulfillment centers as physically easier due to less heavy lifting and fewer hazardous tasks, but more mentally stressful due to the repetitive nature of the work and intense pressure to maintain high productivity. Many workers reported burnout, stress, and dissatisfaction associated with robotic warehouse jobs.
Implications for Future Workplace Safety
These mixed results highlight a critical trade-off in warehouse automation. While robots significantly reduce the risk of severe, life-altering injuries, they simultaneously drive an increase in less-visible ergonomic and repetitive-motion injuries. The researchers emphasize that companies adopting robotics should pay close attention to job design, task variety, and pace management to mitigate these unintended consequences.
Published April 21, 2023, on SSRN by researchers Gordon Burtch (Boston University), Brad N. Greenwood (George Mason University), and Kiron Ravindran (IE University).