A majority of U.S. warehouses lack the operational agility needed to respond effectively to disruptions, according to a recent study from warehouse technology provider Lucas Systems conducted in partnership with Wakefield Research.

The survey gathered responses from 114 U.S.-based supply chain executives about the flexibility of their warehouse automation systems and their ability to adapt to unexpected operational changes.

The findings indicate that many warehouse operations are constrained by rigid systems that make it difficult to adjust to disruptions or new requirements.

Key findings from the survey include:

• 51% of respondents said their warehouse automation systems are not prepared to handle unforeseen operational changes or disruptions.
• 77% said at least half of their warehouse hardware and software systems are too rigid to respond effectively to unplanned disruptions.
• 85% reported experiencing up to 10 significant unplanned disruptions in the past year, while another 7% experienced more than 10.
• 51% said they experience more operational disruptions today than three years ago, following the COVID-19 pandemic.
• Among companies dealing with rigid systems, about 60% reported additional operating costs or losses of 11% to 25% when responding to disruptions or new operational requirements.

Respondents cited several types of disruptions affecting warehouse operations, including system downtime, equipment failures, labor shortages and unexpected demand spikes.

Despite these challenges, most supply chain leaders said adaptable warehouse technology is critical for improving resilience and operational performance.

Additional survey findings include:

• 86% of respondents said adaptable warehouse technology is critical for their operations.
• 72% said reconfiguring their current automation systems to respond to disruptions would require considerable effort.
• Among organizations that have deployed adaptable automation, 26% said those technologies helped reduce operational costs by more than 25%.

The study highlights the frequency of disruptions facing warehouse operations and the difficulty many organizations have adapting existing automation systems to changing conditions.

Lucas Systems said the results reflect growing pressure on warehouse operations to handle volatility, labor constraints and shifting demand patterns while maintaining efficiency and service levels.