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By Chip Yager | Jan. 20, 2026
Putting Automation to Work: From Tedious Tasks to Tangible Triumphs
AI-driven frontline operations will require companies to develop new capabilities that augment their current approach. Previously we explored how Asset Visibility delivers a complete, real-time view of the entire frontline environment, critical to provide AI models with knowledge of the current situation. We then showed how a Connected Frontline organization can leverage AI recommendations to orchestrate teamwork and optimize workflows, driving real-time actions. But there is a limit to what we can do through frontline workers alone – that’s where Intelligent Automation steps in.
As frontline operations grow more complex, businesses increasingly depend on technologies like RFID and machine vision to create ‘super-human’ capabilities. These solutions address labor shortages, improve worker safety, and deliver the accuracy and speed that today’s on-demand economy requires.
The Power of Precision: Automating with RFID
If you asked companies to say what knowledge would have the biggest impact on improving operations, they would quickly say, “Tell me where everything is.” RFID technology does precisely this, enabling systems to track items continuously and without human intervention. RFID has moved well beyond the ‘inventory count’ use case to provide precise location tracking across store floors, shop floors and distribution centers. Leading companies are taking advantage of this today.
Consider the aerospace and defense manufacturer Curtiss-Wright, which faced a seven-day processing time for complex production orders. By implementing an RFID-based solution, they saw bottlenecks as they developed, reacting in real time to shift resources to keep operations moving. The company was able to condense the entire production cycle into just 24 hours, sharpening its competitive edge.
In healthcare, Hull University Teaching Hospital in the UK leveraged RFID to gain real-time visibility of its medical assets, patients and personnel. This automated tracking improved workflows, reduced the time staff spent searching for equipment and allowed caregivers to focus more on patient needs. They estimated that they saved 88,000 hours of labor in the first full year of implementation.
A New Vision for Efficiency
Machine vision technology represents another leap forward, equipping systems with the ability to see, interpret, and act. They see faster, in more detail and can make instantaneous decisions that accelerate operations. This ‘super-human’ capability enables companies to accomplish more than they ever could previously.
Our automation partner Rebl Industries, using a Zebra FS40 barcode scanner and our advanced 3D vision machine vision camera system, developed a solution for a global retailer struggling with mixed-case palletizing. By dimensioning each made-to-order box, the system puts each box on the pallet in the right order, in the best spot. The system automates the physically taxing job of stacking random-sized boxes and improves worker safety and retention.
This kind of automation is also vital in quality assurance. The power equipment manufacturer STIHL, for example, uses Zebra’s machine learning-based software to automate the inspection of its gasoline suction heads, cutting cost, time, and human error from its quality control process. The recycling company Polytag now uses Zebra’s vision tools to achieve nearly 100% accuracy in tracing brand-level packaging waste, demonstrating how automation supports critical sustainability goals and the development of a circular economy. The benefits of machine vision clearly extend far beyond the factory floor to help companies address a range of cross-functional challenges.
Empowering the Frontline with Human-Centered Automation
What sets Intelligent Automation apart is its focus on people. In manufacturing, for instance, tedious and error-prone tasks like visual inspections now receive support from machine vision technologies. The manual process of tracking down lost inventory or equipment is alleviated by RFID overhead readers. Instead of replacing workers, these tools help them perform their jobs more efficiently and accurately, freeing up time for higher-value tasks.
This human-centered design ensures that technology enhances, rather than hinders, the employee experience. Our recent study with Oxford Economics shows that by optimizing workflows, manufacturers saw a 19% boost in employee productivity.
Similarly, transportation and logistics (T&L) companies reported a 21% boost in productivity with better workflows, and retailers reported a 21% improvement in customer satisfaction.
Flexibility to Adapt and Scale
Knowing that it can be challenging to get started with big automation infrastructure projects, Zebra’s approach prioritizes flexibility. Our automation solutions are scalable and designed to integrate seamlessly with existing systems, allowing businesses to evolve without being tied to rigid technologies. They can be built out over time – moving from mobile RFID readers, to fixed portal readers at doors, to overhead coverage of the operations can all be done over time with incremental benefits seen each step of the way.
By weaving together the Connected Frontline, Asset Visibility and Intelligent Automation approaches, businesses can create a fully digitized and optimized operation. Real-time data from assets will inform the domain-specific AI systems that automate tasks, while connected workers and automation orchestrate the entire workflow. This synergy creates the foundation for a future where frontline operations everywhere are intelligent and responsive.
