Using the case study of updating a robotic palletizing operation in a New Zealand oil company, outlines how the reliability of a shopfloor application depends to a great extent on how well the system can respond to unpredictable situations. Explains that the effective use of system and sensor information is critical for the achievement of a well co‐ordinated response. Covers areas such as the gantry system, motion control, information flow, process strategies and adaptive motion strategy. Concludes that the overall goal of the updated system was to increase system availability in container handling and improve safety aspects. As a result of utilizing previous shopfloor experience and effective use of sensor information, a very reliable palletizing operation has been achieved.