When every pallet position counts, unplanned downtime or breakdowns in your automated storage system aren’t just an inconvenience; they’re a costly disruption. From production delays and missed dispatches to increased labour costs, even a few hours of downtime can have a ripple effect across your entire operation.
For warehouse managers, engineers, and executives, maintaining consistent uptime requires more than just good equipment. It’s about proactive design, disciplined maintenance, and smart operational practices.
Below, we explore key strategies to help you keep your Automated Pallet Storage solution, such as Autocube, running at peak performance, day in and day out.
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Build Redundancy into Your System Design
Even the most reliable automation systems experience component wear and occasional faults. Designing for redundancy ensures that a single failure doesn’t bring your operation to a standstill.
Key strategies:
- Multiple lifts: Incorporate two vertical lifts or shuttles modules to ensure one can continue operating if the other is offline.
- Multiple shuttles: Spread workload across several shuttles – this increases throughput and allows one shuttle to be serviced without stopping the system.
- Bypass conveyors and alternative paths: Design layouts that provide backup flow routes if a section becomes unavailable.
Why it matters:
Redundancy transforms downtime from a total shutdown into a manageable maintenance task, keeping your facility productive even under pressure.
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Protect System Reliability with Pallet Integrity
Your automated system is only as reliable as the pallets it handles. Poor-quality or damaged pallets are one of the most common causes of stoppages, leading to pallets getting stuck in the system or even mechanical damage.
Best practices for pallet quality:
- Implement a pallet inspection process: Check for broken boards, protruding nails, or inconsistent dimensions before loading pallets into the system.
- Standardise pallet types: Use only approved pallet formats (e.g., Euro or UK standard sizes) that are compatible with your automation hardware.
- Monitor pallet weight consistency: Overloaded or unevenly distributed loads can stress lifts and shuttles, causing unbalanced movements and potential system errors.
- Train operators to recognise damage early: Small defects caught at the inbound stage can prevent major downtime later.
- Incorporate a pallet integrity scanner: Automate the process by using a pallet integrity scanner which can measure weight, pallet size and load integrity to ensure your pallets are fit for the system
Why it matters:
Ensuring pallet integrity keeps conveyors, shuttles, and sensors operating smoothly, avoiding unplanned stoppages caused by something as simple as a cracked board.
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Implement a Structured Preventative Maintenance Programme
Preventative maintenance is one of the most effective defences against unplanned downtime. The key is consistency and data-driven planning.
Steps to create an effective maintenance schedule:
- Follow system recommendations: Base your schedule on manufacturer guidelines for inspection intervals, lubrication, and part replacement.
- Adjust frequency by usage: High-throughput environments require shorter intervals between checks.
- Log all interventions: Keep detailed records of what’s been serviced, replaced, or adjusted to build a valuable reliability history.
- Schedule during low-demand periods: Plan maintenance windows that align with production downtime to minimise operational impact.
Why it matters:
A proactive maintenance culture can reduce emergency repairs, extend component life, and significantly lower total cost of ownership.
Our MAXIQ software features an SLA software module, providing comprehensive monitoring and reporting on all hardware components to ensure your solution operates at peak performance.
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Optimise Environmental and Operational Conditions
Automated systems are highly sensitive to their surroundings -even small environmental fluctuations can affect performance and reliability.
Environmental control measures:
- Temperature and humidity: Extreme cold, heat, or moisture can affect electronics, lubrication, and metal components and this must be taken into consideration in your maintenance schedule.
- Control dust and debris: Contaminants can impair sensors, bearings, and shuttle tracks – regular cleaning is therefore essential as part of your daily, weekly checks.
- Monitor power quality: Use surge protection and uninterruptible power supplies (UPS) to protect sensitive control systems.
Operational best practices:
- Operator training: Well-trained teams are your first line of defence – they can spot issues early and use equipment correctly.
- Clear access routes: Avoid clutter around entry/exit points to allow smooth pallet flow and easy maintenance access.
Why it matters:
Controlled environments and disciplined operation reduce wear, prevent safety incidents, and maintain system precision.
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Maintain Smart Monitoring and Spare Parts Readiness
The ability to detect issues early and respond fast separates resilient operations from reactive ones.
Monitoring and readiness best practices:
- Implement real-time system dashboards: Track shuttle performance, lift cycles, and fault codes to identify early warning signs.
- Use predictive analytics: Data-driven insights help forecast potential failures before they stop operations.
- Keep critical spares on-site: Maintain an inventory of high-impact components such as motors, belts, sensors, and controllers.
- Partner with a responsive support provider: Choose a supplier with rapid-response service agreements and remote diagnostics capability.
Why it matters:
A combination of real-time visibility and readiness ensures that when issues arise, you’re equipped to respond in minutes -not hours.
Key Takeaways
- Redundancy keeps operations running even when individual components fail.
- Pallet integrity is non-negotiable -consistent, undamaged pallets prevent mechanical and sensor issues.
- Preventative maintenance reduces risk and cost, turning reactive downtime into planned interventions.
- Environmental control protects your investment and ensures smooth mechanical performance.
- Monitoring and spare parts management enable rapid recovery, minimising operational impact.
At Thistle Systems, we’ve seen first-hand how well-designed, well-maintained automation transforms warehouse efficiency. From the initial system layout to long-term service support, every detail plays a role in achieving maximum uptime.
If you’d like to discuss how Autocube’s intelligent design and Thistle Systems’ lifecycle support can enhance reliability across your operation, get in touch with our automation team on 01236 453888.
Looking to Automate your Picking Operations?
If Automation is right for you, however your requirements differ from AutoCube’s offerings, explore our options: Brightpick – A Robotic Order Picking System. From in-aisle robotic picking solutions to fully automated goods-to-person systems, we have a solution that can be tailored to suit your requirements.
