In this article, we’ll explain why warehouse robotics is gaining speed, how SAP EWM supports its adoption, and what companies need to connect the two.
In 2023, Amazon deployed over 750,000 robots in its warehouses — up from 350,000 just three years earlier. Was it a strategic move? Not exactly. It was a necessity to meet the 12% annual growth in global E-commerce demand.
Today, many businesses are relying on robots to keep up with growing demand and labor shortages. But plugging a robot into a warehouse isn’t enough. Without a system that tells it what, when, and how to do something, even the smartest machine will just sit there. This is where the real challenge — and opportunity — begins.
In this article, we’ll explain why warehouse robotics is gaining speed, how SAP EWM supports its adoption, and what companies need to connect the two. You’ll see what works in practice, what to expect during implementation, and how to make sure your robots don’t turn into expensive decorations.
Why Robotics Use Is Rising in Warehouses
Robots are not just for giant retailers anymore. Smaller and mid-sized companies are also adopting automation, and not because it's trendy, but because it pays off. Here are four main reasons why warehouses increasingly use robotics:
- Labor shortages are real. Warehousing jobs are hard to fill, especially in regions with aging workforces or high turnover. Robots can pick, move, and sort goods without shifts, breaks, or sick days.
- E-commerce changed the game. Traditional manual processes became outdated with the demand for same-day delivery, high order volumes, and low tolerance for errors.
- Operations need to scale faster. Seasonal peaks or sudden demand spikes can overwhelm manual teams. Automated systems respond quicker, especially when controlled through intelligent software.
- The tech is no longer experimental. Autonomous mobile robots (AMRs), automated guided vehicles (AGVs), and shuttle systems are more reliable and affordable than even five years ago. Many come with APIs and ready-made integration options for SAP landscapes.
In short, robots are here to stay, not as a futuristic bet, but as practical machines solving very real problems. But to make them work — really work — warehouses need a system that speaks their language.
The Role of SAP EWM in Robotics Management
Robots may do the heavy lifting, but they need direction. Without a system to coordinate their actions, they’re just idle machines waiting for input. SAP Extended Warehouse Management (EWM) is one such system.
SAP EWM acts as the digital backbone of the warehouse. It tracks inventory, assigns tasks, manages exceptions, and keeps everything in sync — across people, robots, and processes.
For companies using robotics, EWM becomes the control tower. It communicates with devices like AMRs, AGVs, shuttle systems, and sorters, handling everything from task distribution to real-time inventory updates.
Let’s break down a few popular types of robotics and how they pair with SAP EWM:
Autonomous Mobile Robots (AMRs)
These robots navigate freely through the warehouse. EWM assigns them tasks like moving bins, transferring packages, or supporting picking processes. The system calculates optimal routes and updates tasks in real time.
Automated Storage and Retrieval Systems (AS/RS)
High-speed cranes or shuttles are robots that store and retrieve items in racking systems. EWM manages the logic: where items go, when they are retrieved, and how to integrate them with the next step (e.g., packing or quality check).
Robotic picking arms
These are used for item picking in E-commerce, pharma, or small parts warehouses. EWM controls picking sequences and tells the robot what to grab, based on order data and inventory position.
Drones
Still an emerging tech, drones are increasingly used for stocktaking. They scan barcodes or RFID tags from above. EWM updates inventory in real time based on what the drones see.
Conveyors and sortation systems
These robotic systems don’t think for themselves, but with EWM in charge, they move goods where they’re needed, reduce walking time, and organize packages for outbound shipments.
Key Features of SAP EWM
Below are the key functions of SAP EWM that support automation and make robotics useful, not chaotic.
Warehouse structure
Before robots can operate, they need to know the warehouse layout. EWM models the entire warehouse — from storage bins to work centers — so robots follow and interact with digital maps. This is the foundation for accurate movement and task execution.
Inbound and outbound processes
Robots involved in unloading, sorting, and/or picking need clear instructions. EWM organizes inbound and outbound flows, task assignments, time management, and traffic management at docks. It ensures robots (and people) don’t get in each other’s way.
Inventory management
EWM keeps real-time records of stock locations and quantities. Robots rely on this to know what to pick, where to put it, and what’s available. No blind spots, no guesswork — every move is based on up-to-date inventory data.
Warehouse task management
This is where the action happens. EWM creates and assigns tasks to machines and operators based on workload, priority, and availability. Whether it’s a robot retrieving a pallet or delivering goods to a packing station, task assignment is smart and automatic.
Warehouse order creation and processing
Tasks are grouped into orders for better execution. EWM builds these orders based on type, urgency, and location. It helps coordinate robotic and human tasks to avoid delays and bottlenecks — for example, combining robot-driven transport with manual repacking.
Labor management
Even with robots, people are still part of the workflow. EWM monitors workforce performance, shift planning, and workload distribution. It ensures that automation fills the right gaps and does not overlap with available labor or create idle time.
Cross-docking and value-added services
For fast-moving operations, robots may bypass storage entirely. EWM supports cross-docking, routing goods directly from receiving to shipping. It also integrates robots into packing, labeling, or kitting processes, turning them into part of the value chain, not just movers.
Yard management
EWM doesn’t stop at the warehouse door. It manages truck arrivals, gate check-ins, and staging areas. Robotic systems can be used outside, too — in unloading zones or trailer transport. EWM keeps everything coordinated, so dock-side delays don’t affect warehouse throughput.
Integration and connectivity
This is what makes robotics possible. EWM connects with different hardware and control systems using standard protocols (like OPC UA, MQTT) and custom APIs. It allows for seamless communication with AGVs, AS/RS, conveyors, and more — giving companies flexibility in choosing tech without losing visibility or control.
Real Results 一 What Companies Gain
Once SAP EWM and robotics start working together, companies see real, measurable improvements across warehouse operations.
- Faster order fulfillment: With tasks automatically created and assigned to available resources — human or machine — orders move faster from intake to shipment.
- Better space utilization: Robotics combined with precise inventory tracking ensures higher-density storage. Fewer errors mean less buffer stock and more room for actual goods.
- Fewer errors: Barcode scans, pick-by-light systems, and robotic handling all reduce the risk of human mistakes. And EWM ensures every task is based on real-time, accurate data.
- 24/7 operations: Robots don’t need lunch breaks. When EWM coordinates their tasks around the clock, companies can keep up with late-night orders, seasonal surges, or global delivery schedules.
- More predictable planning: With everything tracked and logged, forecasting becomes easier. You know how long each process takes, where delays happen, and what to expect during peak loads.
- Lower labor strain: Robots handle repetitive, physically demanding tasks — reducing injuries and freeing human workers for tasks that require judgment or flexibility.
In addition, SAP EWM allows gradual automation, so companies can start with one area (like goods movement or pallet retrieval) and scale up based on business needs.
Types of Warehouses and Industries SAP EWM Serves
SAP EWM can be used across industries and warehouse types, from high-volume distribution centers to tightly regulated production environments.
Industries:
- Retail & E-commerce 一 For handling large volumes, returns, and tight delivery windows.
- Automotive & manufacturing 一 Managing just-in-time production supply and complex parts inventories.
- Pharmaceuticals 一 Ensuring traceability, expiry control, and regulatory compliance.
- High-tech & electronics 一 Supporting small, high-value parts with real-time tracking.
- Food & beverage 一 Coordinating perishable goods, cold storage, and high-speed replenishment.
Warehouse types:
- Manual or semi-automated warehouses 一 Where EWM brings structure and visibility.
- Fully automated facilities 一 With AS/RS, robotic pickers, and conveyor systems.
- Temperature-controlled zones 一 Where precision and timing are crucial.
- Cross-dock locations 一 For fast throughput without storage.
- Production warehouses 一 Where raw materials and finished goods must sync with manufacturing lines.
This flexibility makes EWM a good match not only for big players, but also for growing businesses looking to future-proof their logistics setup.
How to Get Your Robotics Systems Working with SAP EWM
Adding robots to your warehouse is more than just a hardware upgrade — it’s a systems challenge. You can’t simply switch them on and expect things to flow. They need instructions, coordination, and real-time updates — and that’s where integration with SAP EWM comes in.
Challenges
The most common issue is misalignment between the physical and digital layers. A robot may be ready to move a pallet, but if the system doesn’t know where it’s supposed to go, or if the task isn’t properly assigned, things break down fast. Companies also struggle with legacy systems, unclear processes, or robotics vendors that don’t provide ready-to-use connectors.
Another challenge is deciding where to begin. Not all operations benefit equally from automation, and not all robots speak the same “language” out of the box. That’s why the way you deploy SAP EWM — and connect it with robotics — matters.
Deployment options
SAP EWM can be implemented in different ways, depending on your setup, goals, and timeline:
- SAP EWM on SAP S/4HANA (Embedded)
Ideal for companies already using S/4HANA. This option allows smoother data flow and fewer integration points, especially if you plan to scale automation gradually. - SAP EWM on SAP S/4HANA (Decentralized)
Best suited for large, complex warehouses or those running multiple warehouse sites. You gain more flexibility in upgrades and separate performance from your ERP system. - SAP EWM on SAP ERP (Decentralized)
A valid option for businesses not yet ready to move to SAP S/4HANA. While it’s an older setup, it still supports warehouse automation and robotics integration.
Choosing the right path
Start with a simple question: do you already run SAP S/4HANA? If yes, embedded EWM is often the easiest and most efficient route. If not, and your warehousing is complex or high-volume, decentralized deployment (on either SAP ERP or SAP S/4HANA) gives you room to grow and integrate new tech with less disruption.
Review our decision tree to help you choose the right deployment option.
Expert Support for Your Automated Warehouse
SAP EWM and robotics work well together — if integrated correctly. But getting there takes more than plugging things in. It requires smart planning, precise configuration, and a clear understanding of both your warehouse and your tech stack.
At LeverX, we help companies bring their automation goals to life with SAP EWM. Here’s what we offer:
- Help choosing the best deployment model for your needs
- Full-cycle EWM implementation and configuration
- Robotics integration with real-time task and inventory management
- Support for AS/RS, AMRs, AGVs, and more
- System audits for underperforming setups — with clear fixes and upgrades
- Ongoing support and optimization as your operations grow
Are you already running SAP EWM, but not seeing the value you expected? We’ll audit your system, find what’s slowing things down, and help you get it back on track.
For a free consultation on automating your warehouse with SAP EWM, contact our team.
