Final 100 Feet: Why SLAM automation delivers big returns

All parts of warehousing operations are important, but in today’s e-commerce and omnichannel environments, many could argue that the final 100 feet of operations is the make-or-break zone. This is the spot where human errors and lack of speed can lead to costly bottlenecks, chargebacks and lost customers. The tasks of scan, label, apply and manifest—or SLAM—are critical to fulfillment success.

That’s why many operations have put new focus on automating their SLAM lines. When you automate, you optimize this critical final 100 feet of warehousing space. Even better, the investment in SLAM automation is on the relatively low side, and one that can deliver a return on investment in as little as one year.

While an argument can be made for automated SLAM in a variety of industries, it shines brightest when high-volume operations put it to work. Fulfillment operations, e-commerce and omnichannel with a high mix or product types and packages, will find their money well spent.

“If my business is packaging and shipping only 25 boxes a day, automated SLAM equipment won’t pay off,” says Don DeLash, logistics sales director at SICK. “But if you have a good deal of volume, lots of things must happen correctly in that final 100 feet of warehousing. Automated SLAM systems can help in multiple ways.”

Trey Tooley, field application engineer with Bastian Solutions, says that industries from healthcare to third-party logistics (3PL), and many in between, can be a good fit for automated SLAM lines.

“Any operations where you have a lot of packages and a need for labeling quickly, consistently and accurately make sense,” Tooley says.

Many brands have automation geared toward that final 100 feet. Here’s what that can look like, and how it can help.

The elements of SLAM

At its most basic, the SLAM line includes automation that scans packages to identify what it is managing. This might include a 1D or 2D bar code, RFID or pattern identification using vision technology. Once the system has scanned and captured that data, it sends it to a host system to essentially say “I have this package.”

The host system then sends the shipping information to labeling, where a machine prints the label with human readable and bar code data so the company can track the package from there. Automated equipment applies the label and sends it outbound to manifesting. Software here confirms and records all the steps and pieces leading up to manifesting, then builds a delivery manifest.

All this equipment is tied into a controller or computer that is linked to a host system like a warehouse management system (WMS). This is the link that holds the entire process together, and ensures outbound packages are going where needed.

Getting integration right is crucial. SLAM automation will tie into your host platform, such as a WMS, but usually will also require a middle layer, such as warehouse execution system (WES) or warehouse control system (WCS), that can serve as a bridge between your WMS/legacy system and the automation. This can often be a point where projects stall, so working with an experienced integrator will be key for success.

Beyond the baseline SLAM equipment, several areas can be added on to the line to make it even more effective. “SLAM lines are evolving, and companies are continuing to develop technology,” DeLash says.

SLAM can—and often does—include weighing and dimensioning automation. “The addition of weighing and dimensioning can quickly accelerate your ROI,” says DeLash. “It will allow you to choose the smallest possible packaging and use the least amount of fill to keep the costs down.”

This newer, highly accurate addition allows SLAM lines to manage irregular packaging sizes and shapes easily. Today’s automation also allows you to rate shop, if you use multiple carriers.

“The SLAM equipment will print a label and pick a carrier based on the best pricing or route,” says Aaron Taylor, director of marketing at Cubiscan. “When it reaches manifesting, it will direct the package on to the right carrier.”

Taking the entire SLAM line one step further, you can also integrate it with the tasks and equipment that feed into it. “The most compelling ROI for SLAM is integrating it as an end-to-end automated solution,” says Pat Hanrahan, vice president of business development at the Numina Group. “The WES optimizes order releases and directs picking into shipping cartons, which then feed into SLAM on a conveyor.”

If it’s an extremely high-volume operation, there’s also opportunity to run multiple SLAM lines, receiving cartonized product from numerous automated lines leading into them.

“The WES can direct packages based on class,” says Hanrahan. “You have the chance for dedicated throw-on lanes for cases and can batch pick across multiple orders and carriers, with automated weighing and dimensioning, and sorting for the carrier.”

Another option is to add on a quality control check with image capture. “This is a slam dunk,” said Tooley. “It ensures accuracy, and this can have a direct impact on customer satisfaction.”

Not every company will have the ability or will to go all in with full automation out of the gates. “You can do it piece by piece if that’s easiest,” says Taylor. “We recommend starting from the dock line and working backwards. Otherwise, you can get bottlenecks.”

Your decision on how to approach the design will largely depend on budget and the manpower to dedicate to implementation. A greenfield facility, for instance, is an opportune time to go end-to-end, but some experts argue that automating the full line is always ideal.

“For the core tasks of a SLAM line—the scanning, labeling, applying and manifesting—it makes the most sense to automate fully,” said Tooley. “But you can add on the scales and additional quality control components later on.”

The advantages of automated SLAM lines

With automated SLAM equipment in place, you can begin to enjoy the benefits. These range from labor cost savings to materials cost savings, making more out of your footprint, and meeting your sustainability goals. When put together, you can achieve return on investment in relatively short order.

One of the places where SLAM comes through is its ability to employ right-size packaging and void fill. Customers have demonstrated their dislike for big boxes for small items with a copious empty space. Having automation that can eliminate that issue can help you gain/keep customers, as well as save on transportation costs.

There’s also the argument that by choosing the right packaging and fill, you can reduce your returns due to damage, which can be costly. The National Retail Federation reported that 2024 returns totaled $890 billion, or nearly 17% of annual sales. In the same report, 67% of surveyed customers noted that a negative returns experience would discourage them from shopping again with a retailer.

Most SLAM automation will be packaging fill and container agnostic, which is critical. This is an area that is constantly evolving, and you need automation that is flexible enough to adapt to changing and different materials.

Automation can also help companies meet an increasing number of international packaging waste reduction standards and ESG goals. By reducing packaging materials now, you set your company up for success in the future as regulations evolve.

“When you are manually packing, there are many steps and opportunities for mistakes,” says Hanrahan. “If you send the wrong package to a carrier, or to a customer, you may be looking at thousands of dollars in returns, and damage to your reputation. Manual SLAM operations are time intensive and error prone, and they don’t scale well when you reach peak times of day or season.”

All these factors add up to a good argument for SLAM automation, but it’s the increased throughput that sells most of the equipment.

“If you are a fully manual operation, you’ll typically handle six packages a minute,” says DeLash. “If you semi-automate, that increases to 15 per minute, and if you fully automate, you can expect to handle 30 packages per minute, give or take.”

Add in increased accuracy and a reduction in work duplication, and you get a “time costs money” valuation to SLAM automation. This increase in speed can amount to an ROI within six to 12 months, depending on volume.

From a labor standpoint, automated SLAM lines can lead to a reduction of headcount, but Taylor recommends against that calculation. “Companies make decisions based on investment in people or processes,” he says. “From a labor perspective, automation gives you an opportunity to re-allocate people to more engaging jobs. Automation can be a scary word to employees, but it can be an opportunity to grow a career and learn new skills.”

Perhaps the biggest gain to SLAM automation, according to Tooley, is the peace of mind that comes with reliability.

“Shipping accuracy has a big impact on customer satisfaction,” he says. “SLAM lines improve your efficiencies and ensure the right package gets to the right customer, every time.”