Riding the robot revolution

Allan’s journey began in 2006 at DHL Supply Chain’s Preston Brook site in northwest England, where he started as a warehouse operative. Over 14 years, he worked his way up through various roles – forklift driver, high-rack reach truck operator, and warehouse admin – gaining hands-on experience and a deep understanding of logistics operations. Fortunately for Allan, his career coincided with the explosive growth of robotics in warehousing, and his self-driven interest in the field of IT and robotics truly shaped his path.

In 2021, Allan moved to DHL’s warehouse in Skelmersdale, a multi-customer site midway between Liverpool and Manchester, where he still works today. He quickly became a “super user” with deep knowledge of the warehouse content management system and trained in problem-solving pertaining to the software, for two well-known British beauty customers. His curiosity and initiative quickly caught the attention of senior management, leading to a series of promotions and project leadership roles in robotics integration.

Allan’s transition from manual operations to robotics was sparked by a fascination with automation. “I’ve always been interested in technology,” he says. “I built computers as a kid and taught myself IT skills over the years.”

At Skelmersdale, Allan played a key role in implementing Six Rivers Systems – assisted picking robots that doubled productivity from 150 to 300 units per hour. He immersed himself in the technology, asking engineers questions, learning backend systems, and even training as a robot engineer to maintain the fleet.

Allan’s career at DHL caught some of the earliest waves of warehouse robotics. These included AI, vision-based sorting, and autonomous navigation. Later, cloud computing, machine learning, and the Internet of Things (IOT) came into popular use. Most recently, collaborative robots such as Locus bots have become widespread.

The e-commerce boom has fueled this unprecedented demand for faster, more precise order fulfillment – and automation has become essential to keeping pace. Labor shortages in many markets accelerated adoption. But rather than replacing people, robotics is helping create new types of jobs in logistics: Analysts estimate that warehouse automation will continue to expand by around 15–18% a year through 2030, opening opportunities for workers skilled in managing, maintaining, and improving these systems. 

For Allan, the rise of robotics in his workplace was nothing short of fascinating. And his biggest challenge wasn’t using, adapting, or implementing the technology – it was helping some of the people he worked with to adjust to the changes.

“Getting colleagues to shift from manual to automated systems could be tough at times. It really depended on how open that person was to technology,” Allan recalls. They ran mock shifts, held hands-on training, and stayed on the floor to support employees. “Everyone learns differently, and we had to meet them where they were,” he says.

As much as he loves tech, Allan is quick to dispel the myth that robots are replacing people. “These robots don’t replace the human element – they assist it,” he explains. “You still need someone to pick the item, scan it, and confirm the action. The robot just helps you do it faster and safer.”

Allan sees robotics as a tool for empowerment. “It’s not about taking jobs away. It’s about making the job easier, reducing errors, and improving safety. You’re not pulling a heavy trolley anymore – you’re following a robot. It’s a smarter way to work.”

His efforts paid off. After a successful peak season, Allan was promoted to IT Manager, overseeing 11 customer contracts and mentoring new analysts. In 2024, he helped launch the contract for Sephora in Coventry, UK.

Today, he’s leading the robotics implementation for the world‘s second-largest cosmetics company as part of DHL’s Accelerated Digitalization (AD) team.

Allan’s story is a testament to how curiosity and initiative can shape a career. From the warehouse floor to leading robotics projects, he’s helping DHL evolve while staying true to what matters most: supporting people and delivering excellence.

Digital by Default is DHL Group’s commitment to using digitalization to accelerate sustainable growth. As part of our Strategy 2030, we aim to empower our people with easy access to digital tools, enhance customer experience through digital touchpoints, optimize operations with resilient technologies, and advance sustainability through data-driven transparency. By using AI and automation, we implement state-of-the-art technology to support our teams and achieve better results. The Digital by Default mindset positions our Group to deliver excellence, stay competitive, and remain a leader in global logistics.