Podcasts Archives - Material Handling Wholesaler

AI-Enabled Warehouses: Insights from Dr. Jim Tompkins

Wed, 22 Jul 2026 13:05:03 +0000

Welcome to this episode of The New Warehouse Podcast, featuring Dr. Jim Tompkins, chairman and founder of Tompkins Ventures. The company connects businesses with an ecosystem of experts through flexible, results-based engagements. Tune in and hear Tompkins explain why artificial intelligence is moving beyond isolated tools and into enterprise design. Next, he outlines four stages of AI maturity and their implications for supply chain leaders. Tompkins closes with the data, cybersecurity, and leadership disciplines required to build an AI-enabled organization grounded in warehouse operational reality and practical business needs. From Tool to AI-Enabled Warehouse Tompkins maps AI across four stages. It begins as a tool that improves existing work. It becomes a worker when it completes assigned tasks. Memory, agentic AI, and autonomous action then make it a partner. The fourth stage is more disruptive because companies redesign themselves around the technology. Tompkins explains, “And we started asking the question, ‘How do we reorganize the company around AI?” And now, oof.” That shift changes both structure and strategy. Leaders retain core capabilities while using AI and outside experts for the rest. An AI-enabled warehouse does not make leadership less important. It makes leadership faster, more selective, and more focused on the next critical move. The competitive stakes are severe. “Because if your competition does AI and you don’t, you’re toast.” While many companies contemplate job loss from AI, Tompkins adds, “I mean, you’re not gonna lose 70% of your jobs; you’re gonna lose 100% of your jobs.” Pointing out that companies don’t pursue AI to reduce headcount, they must do it to save jobs. With AI, Warehouse Decisions Move Into Real Time AI-enabled warehouses begin before the truck reaches the dock. It can improve scheduling, yard movement, door assignments, and container placement. Tompkins argues that poor flow also worsens the perceived driver shortage. “The driver only gets paid when he’s driving, and he’s gonna spend three hours a day sitting in some lounge someplace.” Inside the building, AI can adjust labor and workflows as conditions change. Tompkins describes a shift that expected 48 people but received 46. AI could reallocate those workers for the next two hours. Later, it could shorten picking waves and isolate 22 urgent orders. Another example creates a temporary fast-pick line for two shirts and one baseball. That line could process 7% of the day’s orders within an hour. The applications extend through slotting, picking, sortation, staging, and shipping. “And none of this is theoretical. Everything I’ve said in the last two minutes, we’re doing. We’re absolutely doing with AI today.” Becoming Bigger Than the Payroll The fourth stage combines AI with fractional expertise and rented capabilities. AI-enabled warehouses retain core competencies while accessing specialists, software, infrastructure, and services as needed. Tompkins explains the scale of that model: “Because what we do is we have the payroll of maybe a thousand people, but the fact of the matter is we’re having the impact of twenty thousand people.” Human responsibility does not disappear. AI handles retrieval, pattern recognition, summarization, optimization, and monitoring. People remain essential when decisions involve values, priorities, relationships, risk, or trade-offs. Tompkins offers a clear rule: “If it’s something that has a right answer, let AI do it.” He continues, “If it’s something where you’re looking for a reasonable answer, ask the human to do it, because AI doesn’t have the capability of dealing with emotions and risk and relationships; obviously the human does.” That model depends on quality data and strong cybersecurity governance. Key Takeaways AI maturity progresses from a tool to a worker, partner, and enterprise operating model. Competitive planning cycles are shrinking from five years to four weeks. AI can reallocate 46 workers, expedite 22 orders, and process 7% of daily volume within one hour. Fractional expertise can give a 1,000-person payroll the impact of 20,000 people. AI should handle clear answers, while humans own judgment, relationships, risk, and trade-offs. The New Warehouse Podcast AI-Enabled Warehouses: Insights from Dr. Jim Tompkins

The post AI-Enabled Warehouses: Insights from Dr. Jim Tompkins appeared first on Material Handling Wholesaler.

Approachable Warehouse Automation from Big Joe

Mon, 20 Jul 2026 12:42:28 +0000

Welcome to another exciting episode of The New Warehouse Podcast. In this episode, Kevin welcomes Nick Malewicki, General Manager of Autonomous Solutions at Big Joe, to discuss how the company is making warehouse automation more accessible. Celebrating its 75th anniversary, Big Joe has built its reputation on practical material handling equipment. Now, it is bringing that same philosophy to autonomous solutions. Approachable Warehouse Automation Starts with Simplicity Having spent nearly two decades on the customer side purchasing automation, Nick designed Big Joe’s autonomous solutions around real operational challenges instead of ideal conditions. Rather than forcing warehouses to adapt to automation, the equipment is designed to fit existing workflows. As Nick explains, “Deployment, we measure it in days, not years. It works in your existing workflow instead of forcing you to redesign your facility around it.” With the operator and operation in mind Big Joe’s dual-mode equipment allows for easy switching between manual and autonomous operation. Nick summarizes the company’s approach best when he says, “Approachable really means removing that complexity and delivering a machine that gets to work from day one.” Instead of requiring specialized engineers or lengthy integration projects, the goal is to make automation feel like another piece of material handling equipment rather than a complex technology project. Building Automation Around Real Warehouse Operations Nick explained that Big Joe focused on eliminating many of the infrastructure requirements that often delay automation projects. The company’s autonomous vehicles require no magnetic tape, floor-mounted QR codes, or reflector installations. Instead, they rely on embodied AI and advanced perception to navigate existing environments. As Nick explains, “We purposely built for those brownfield applications, those older facilities, older warehouses, that may not be easily conducive to automation.” That philosophy also extends to navigation. The system can identify multiple North American pallet types and even detect pallet openings hidden behind stretch wrap, reducing unnecessary exceptions. Nick reinforces the importance of solving real-world problems by noting, “These are actual customer facilities that exist, and we are up for those challenges.” By embracing imperfect environments rather than avoiding them, Big Joe is reducing one of the biggest barriers to warehouse automation. Start Small, Scale with Confidence Most recently, the company introduced four autonomous vehicles. They include, the AP44 autonomous pallet truck, ATC100 tugger, ASC40 stacker, and ACV40 three-wheel counterbalance forklift. “Starting semi-autonomous really allowed us to then build upon that and offer customers three vehicles in one.” Together, they enable operations to expand automation as confidence gradually grows. Nick recommends taking “an approach of crawl, walk, run” by starting with repetitive pallet movements before introducing additional autonomous workflows. He finds, “Our customer has an interest for that full autonomy, but a lot of time’s they’re not ready. Either they have no automation or maybe just starting their journey.” He believes the AP44 provides an ideal entry point for warehouses. Primarily, it automates repetitive transportation tasks while allowing manual operation whenever needed. Having a piece of equipment that can start semi-autonomous, allows operations to learn more about how automation actually fits within their workflows. Key Takeaways A crawl, walk, run strategy helps companies begin with simple workflows before expanding automation across their operations. Starting with semi-autonomous material handling equipment allows operations to learn how automation fits into their workflows. Big Joe intentionally designed its solutions for brownfield warehouses, eliminating the need for reflectors, magnetic tape, QR codes, and major infrastructure changes. Big Joe’s approach centers on approachable warehouse automation that reduces complexity instead of adding it. The company unveiled four autonomous vehicles designed to support horizontal transport, vertical movement, towing, and forklift applications. The New Warehouse Podcast Approachable Warehouse Automation from Big Joe

The post Approachable Warehouse Automation from Big Joe appeared first on Material Handling Wholesaler.

Social Commerce Fulfillment Powers Modern 3PL Success

Wed, 15 Jul 2026 12:32:07 +0000

In this episode of The New Warehouse, Kevin welcomes Jing Jing Chen, Vice President of Growth at Basic 3PL. They discuss how the rapid rise of social commerce is transforming fulfillment operations. Jing Jing shares how Basic 3PL has built an automation-first fulfillment network that combines robotics, technology, and skilled employees to help brands thrive in an increasingly fast-paced e-commerce landscape. Social Commerce Fulfillment Requires a New Approach Social commerce has fundamentally changed how products move through the supply chain. Instead of predictable order volumes, fulfillment providers must be prepared for demand that can surge within minutes after a product goes viral. Basic 3PL has intentionally designed its operation around the challenge most 3PLs fight against. Rather than treating demand spikes as exceptions, the company assumes they will happen every day. As Jing Jing explains, “This is our norm. So the reason why we named it Basic was that this is our basic, our standard. This is our day-to-day. We build from peak.” That philosophy influences everything from warehouse design to staffing and technology investments. Consumer expectations continue to accelerate this shift by increasingly expecting next-day delivery. Jing Jing notes, “You have the instant fulfillment expectation.” She adds that “Shoppers want their packages now. Who wants the packages tomorrow, not five days, seven days?” However, meeting those expectations requires infrastructure capable of processing unpredictable demand without sacrificing fulfillment speed or accuracy. Automation Creates Speed Without Replacing People Automation plays a central role in Basic 3PL’s strategy, but Jing Jing emphasizes that robotics work alongside people rather than replacing them. Robots handle repetitive movement throughout the warehouse while employees focus on oversight, troubleshooting, and operational decision-making. As she explains, “Our robotics are designed to be our pick packers, so they do the heavy lifting. They’re the ones that are retrieving the goods, the inventory from the shelves, and bringing it down to the human level.” The result is faster throughput while reducing physically demanding work. She also notes that automation doesn’t eliminate the need for people because “it removes the heavy lifting from a human labor, but you still need very much a human factor… to react with any troubleshooting and manage the facility.” This hybrid model extends beyond the technology itself. Employees are cross-trained to work across multiple functions, allowing labor to shift wherever demand is greatest. Combined with robotics, this flexibility enables the company to maintain same-day fulfillment while managing increasingly unpredictable order volumes. Rather than viewing automation and labor as competing strategies, Basic 3PL treats them as complementary parts of a modern fulfillment operation. Building Infrastructure for the Future of Social Commerce Fulfillment As social commerce continues to grow, fulfillment providers must think beyond warehouse capacity. They need scalable technology, intelligent inventory placement, and networks designed to support brands of every size. Basic 3PL has invested heavily in all three, expanding to more than 25 warehouse facilities across the United States while building infrastructure that can quickly adapt to changing demand. Jing Jing believes technology will separate tomorrow’s logistics leaders from the rest of the market. “We want to be the anchor of support to social commerce because we have the ecosystem and infrastructure built for this.” She also recognizes that many growing brands lack dedicated logistics expertise, making accessible technology increasingly valuable. As Basic 3PL expands its offerings, such as Basic Go, the goal is to provide emerging businesses with enterprise-level fulfillment capabilities. Looking ahead, Jing Jing sees innovation as essential rather than optional. “You have to be technology forward. If you don’t have the technology in place, then it’s quite a stretch to get to where you need to based on the demand today.” As consumer expectations continue to rise, modern fulfillment will depend on technology, automation, and flexible operations working together to deliver speed without sacrificing service. Key Takeaways Social commerce has created unpredictable demand for fulfillment, requiring a different operational mindset. Automation improves warehouse speed while allowing employees to focus on higher-value operational work. Cross-trained employees provide flexibility during demand spikes and peak seasons. The New Warehouse Podcast Social Commerce Fulfillment Powers Modern 3PL Success

The post Social Commerce Fulfillment Powers Modern 3PL Success appeared first on Material Handling Wholesaler.

Warehouse Automation Strategy Starts with Software

Mon, 13 Jul 2026 13:17:54 +0000

Welcome to this episode of The New Warehouse Podcast. In this episode, we welcome two guests. Kyle McCarty, Sr. Field Application Engineer at Toyota Automated Logistics, and Jeff Messenger, VP of Reverse Logistics and Facilities/Maintenance/Eng at Pattern. Both companies are at the absolute forefront of transforming material handling and supply chain logistics. Today, we dive into how modular frameworks, virtual testing, and a software-first approach. The discussion highlights how operations of all sizes can scale efficiently, minimize implementation risks, and successfully optimize their workflows before making major capital investments. Warehouse Automation Strategy, Not Shiny Objects Warehouse automation is no longer a luxury reserved only for massive corporate enterprises. Accessibility has expanded dramatically across the industry, but physical hardware alone is no longer the true differentiator. The next wave of industry innovation is being driven entirely by intelligent, highly adaptable software frameworks. Smaller, targeted footprints are now emerging as the absolute best operational fit for small to medium businesses. Messenger explains that automation should never become a distraction from operational excellence. “I think we leverage our experience pretty effectively to not just chase shiny objects or new tech when it hits the market or gets exciting.” Instead, the focus remains on long-term reliability, maintainability, and operational flexibility. He also notes, “Designing in reliability from the start is definitely a big theme.” Toyota Automated Logistics complements that philosophy through collaborative design. As McCarty explains, “Ultimately, we want something that will be there for the long term to help the business grow.” Rather than selling technology, the team works to understand business goals before recommending automation solutions. Collaboration Unlocks Better Automation Solutions Messenger credits that collaboration for uncovering options his team didn’t know existed. “Something not a single one of us at Pattern were aware of were shoe sorters that were bi-directional.” He added, “It really unlocked our ability to be a true, closed-loop, end-to-end cross-dock if we wanted to.” McCarty emphasized that strong relationships make those discoveries possible. “You need to do a ton of relationship building and understanding and really get into the meat of your operations and the long-term view.” Additionally, he stresses the value of working directly with customers: “Those in-person meetings are invaluable.” McCarty adds, “You can learn more in an hour on site than you can in ten virtual meetings.” Those conversations ultimately produce automation designed for today’s operations and tomorrow’s growth. The Future of Automation Is Flexible and Software-Driven Both guests agreed that warehouse automation is becoming more accessible, but smarter software will drive the next wave of innovation. Modular technologies, AI, simulations, and workflow automation will allow companies to improve operations before making major capital investments. McCarty sees flexibility becoming the defining trend. “I think that flexibility, with modular solutions, is really the name of the game for the future.” He also noted that automation is becoming attainable for more organizations as “you’re now seeing a lot more, smaller solutions that are gonna be best fit for small to medium businesses.” Messenger believes software should always come first. “To think about automating the software and the workflows first and the hardware second or last.” He reinforced that philosophy with a simple rule: “The last step you should take is to bolt something down to the ground. Bolting things to the concrete comes with a lot of trade-offs.” By automating workflows first, companies gain flexibility while allowing hardware investments to support proven operational improvements. Key Takeaways Design an automation framework around immediate business requirements and long-term scaling constraints. Build deep partnerships between operators and automation vendors; direct on-site discovery is irreplaceable. Map, simulate, and finalize your software architecture and workflows completely before selecting physical hardware. Utilize simulation and virtual testing tools to validate configurations before investing capital. Focus on flexible, scalable solutions; smaller, modular systems are highly effective for medium-sized operations. The New Warehouse Podcast Warehouse Automation Strategy Starts with Software

The post Warehouse Automation Strategy Starts with Software appeared first on Material Handling Wholesaler.

Barrett Distribution Centers: How 3PLs Build Trust to Retain Brands

Wed, 08 Jul 2026 14:49:23 +0000

Welcome to this episode of The New Warehouse Podcast! In this episode, Kevin welcomes Mark Healy, Vice President of Customer Solutions at Barrett Distribution Centers, Inc., to discuss the dynamic world of third-party logistics. Barrett Distribution Centers is a privately held, third-generation, omni-channel fulfillment and managed transportation provider founded in the early 1940s. Operating 19 strategic facilities across the United States, Barrett specializes in scaling alongside emerging and established brands across retail, wholesale, and direct-to-consumer channels. Healy shares his extensive 30-year industry perspective on why brands leave 3PL providers, the critical importance of proactive communication, and how to operationally align warehouse teams to ensure long-term client retention. Uncovering the Root Causes of 3PL Dissatisfaction When brands face challenges with their logistics providers—such as delayed shipments, inventory inaccuracies, or missed service-level agreements—they often look to switch to a new 3PL. However, Healy emphasizes that switching providers is a painful, costly disruption that may not actually solve the core issue. “I’m always looking to understand what is going to be successful for our customers or prospective customers and to figure out a solution or a path to help them get there.” True customer solutioning begins with diagnosing whether the friction stems from operational failures or a deeper lack of mutual transparency and forecasting. “Have you really sat down with your current 3PL and really, really done a deep dive on this?” Healy frequently asks prospective clients during initial discoveries. By pushing brands to analyze their current relationships, logistics leaders can uncover whether miscommunications—like unannounced flash sales or poorly optimized pick paths for slower-moving SKUs—are contributing to the breakdown. Moving Beyond the Toolbox via Proactive Communication The modern fulfillment landscape has experienced an incredible proliferation of technology, from advanced analytics platforms to complex warehouse automation. Yet, Healy notes that tools are only as effective as the strategy behind them, and true differentiation in the 3PL space comes down to how providers interact with clients. Brands ultimately seek a strategic partner that can look around corners and act as an extension of their business rather than a passive vendor. “The toolbox has just gotten bigger. Now, where you set yourself apart in any perspective of your life, whatever you might do, regardless of whether you’re in the world that I’m in or some other position, it’s understanding how you use the tools.” Providers must use their analytics to proactively advise clients on cost-effective packaging, safer pack-outs, and carrier cutoffs to actively drive business growth. Combating Customer Apathy in Warehouse Operations Connecting front-facing customer feedback directly to the physical warehouse floor is a critical operational requirement for sustaining healthy partnerships. Barrett uses regular client surveys, detailed onboarding processes, and hyper-care periods to ensure full operational alignment. Healy adds, “If we do a good job of listening and defining what is most important to the customer… then everyone is going to be happy, and you’re going to move forward in your relationship. There’s always going to be a cost, but it isn’t just a cost—it’s value.” A quiet client is not necessarily a satisfied one; a lack of communication can often signal that a brand feels neglected and is quietly evaluating alternatives. “Where professional teams lose out is when their fan base has become apathetic. You can’t have an apathetic customer.” To combat this, fulfillment leadership must maintain a consistent, year-round communicative cadence, checking in regularly, whether a brand ships one order or 100,000 orders a day, to resolve issues before they reach a tipping point. Key Takeaways from Barrett Distribution Centers The Pain of Transition: Moving 3PL providers is a highly disruptive process that requires deep discovery to determine whether problems are rooted in operational failures or poor visibility. Proactive Account Management: Leading fulfillment partnerships rely on “looking around corners” to optimize packaging, manage transportation, and protect retail compliance scorecards. The Danger of Client Apathy: Quiet accounts require proactive outreach; structured cadence and comprehensive customer surveys keep relationships active and healthy. Year-Round Scaling: Successful peak season preparation is not a seasonal scramble but a natural extension of consistent weekly or monthly forecasting habits. The New Warehouse Podcast Barrett Distribution Centers: How 3PLs Build Trust to Retain Brands

The post Barrett Distribution Centers: How 3PLs Build Trust to Retain Brands appeared first on Material Handling Wholesaler.

Interact Analysis: Inside the 2026 Warehouse Automation Market

Mon, 06 Jul 2026 12:55:50 +0000

Welcome to another exciting episode of The New Warehouse Podcast. In this episode, host Kevin sits down with Rueben Scriven, Research Manager at Interact Analysis. Interact Analysis is a premier market intelligence firm providing clarity to the complex warehouse industry. This discussion dives deep into the findings of their mid-year warehouse automation report, exploring market shifts, regional trends, and emerging technologies. This episode provides a vital roadmap for operators looking to future-proof their supply chains in a changing landscape. The Evolution of Pouch Sortation and Segment Shifts Sectors like food and beverage are experiencing unexpected acceleration, driven by smaller product quantities and rising logistical complexity. Conversely, the apparel sector is entering a cooling period following a massive pandemic-era investment boom. Admittedly, Rueben Scriven notes that “part of this update is us putting our hands up and saying that we’ve probably got it a little bit too aggressive” regarding previous apparel forecasts. Amid these shifts, traditional technologies are finding entirely new life outside of their original applications. Pouch sortation systems, historically confined to apparel warehouses, are rapidly expanding into healthcare, pharmacy, and parcel facilities to maximize overhead spatial efficiency. Scriven highlights, “We’ve effectively lifted our projections a bit by accounting for the fact that we’re seeing more use cases of pouch outside of the apparel sector”. This expansion proves that old design paradigms are shifting, and, as Scriven states, “this prophecy…from 10 years ago is starting to become a little bit more grounded in truth.“ Contract Innovation Fuels High 3PL Automation Growth Third-party logistics (3PL) providers are adopting automation at a historically high rate. The industry is overcoming this barrier through flexible co-investment frameworks and Robotics-as-a-Service (RaaS) models. Scriven explains the historical bottleneck by noting that “Contract lengths tend to be too short to justify automation investments. Now, there have been several factors recently that have made automation more attractive.” Furthermore, macroeconomic shifts and tariff uncertainties have prompted more companies to outsource their supply chains, leading to a net increase in logistics investments. Scriven observes that “3PL saw more companies outsourcing their logistics because of the uncertainty around tariffs and how tariffs would affect logistics”. This influx of capital allows 3PLs to actively integrate advanced robotics, changing how they position themselves to customers. As the market evolves, Scriven points out an overarching trend where “this prediction is starting to come true” regarding the ultimate convergence of system integrators and 3PL providers. The Warehouse Automation Market is Moving from Custom Engineering to Modular Plug-and-Play Systems The fundamental nature of system integration is changing as the industry moves toward rapid deployment models. The market is actively shifting away from highly customized, rigid engineering projects toward standardized, modular systems. Scriven highlights this baseline change by stating, “We’re seeing this shift in the industry away from highly customized systems more towards more modular, plug-and-play systems”. Rather than bending unique steel and writing bespoke software code for every warehouse, system integrators are now configuring highly pre-designed platforms. Scriven elaborates that “10 years ago, an automated system was highly customized. Steel was bent for that particular project, and code was written for that particular project”. This evolution drastically lowers traditional deployment costs and reduces integration complexity. Both of which end-user surveys reveal are the single largest barriers to automation adoption. Rather than building things from scratch, the modern landscape is dictated by predefined technology stacks, or as Scriven summarizes, “the integrator is configuring them rather than kind of customizing them”. Key Takeaways on the Warehouse Automation Market The Final Frontier: Robotic piece picking is hitting an inflection point. Vendors natively integrate arms into wider systems rather than treating them as an afterthought. The Integration Barrier: End-user surveys reveal that integration complexity, not budget or ROI, is the primary obstacle preventing automation adoption. The 3PL Convergence: Automation providers are increasingly building and running their own facilities, signaling a structural convergence between 3PLs and system integrators. Micro-Fulfillment Resurgence: Following a boom-and-bust cycle, grocery micro-fulfillment centers (MFCs) are seeing renewed interest led by large-scale rollouts from giants like Walmart. The New Warehouse Podcast Interact Analysis: Inside the 2026 Warehouse Automation Market

The post Interact Analysis: Inside the 2026 Warehouse Automation Market appeared first on Material Handling Wholesaler.

Warehouse Leadership Lessons from LesserEvil

Wed, 01 Jul 2026 12:42:47 +0000

Strong warehouse leadership extends beyond productivity metrics and operational efficiency. It creates an environment where employees feel valued, trusted, and empowered to contribute every day. In this episode of The New Warehouse Podcast, Kevin sits down with Allen Avery, Senior Manager of Warehouse Operations at LesserEvil, to discuss how the rapidly growing better-for-you snack company has built a warehouse culture centered on empathy, accountability, and continuous improvement. From hiring the right people to developing future leaders and embracing new technology, Avery shares practical leadership lessons that have helped LesserEvil scale while maintaining a highly engaged workforce. Warehouse Leadership Begins with Hiring Great People LesserEvil has experienced remarkable growth during Avery’s five years with the company. The business now operates roughly 500,000 square feet of warehouse space across multiple facilities, runs 24 hours a day, six days a week, and keeps trucks moving almost continuously to support production and customer demand. Rather than focusing solely on experience, Avery believes long-term success starts with hiring people who fit the organization’s culture. As Avery explains, “We make sure we hire for attitude over skill. We don’t want people who are going to come to work and be miserable every single day.” Avery emphasizes, “We try to lead with empathy and dignity, and understand that people outside of work have really important lives.” This mindset helps LesserEvil build a warehouse culture that supports rapid growth without sacrificing employee engagement. Great Warehouse Leadership Develops Future Leaders Leadership development begins long before someone receives a promotion. “I remembered the way every bad boss ever made me feel. And I swore up, and down I would never make anybody feel that way.” Rather than simply promoting the highest-performing forklift operator, Avery looks for employees who think proactively, solve problems, and help improve operations before issues escalate. His first evaluation question is simple: “First and foremost, are they bringing me problems or are they bringing me solutions?” Avery also encourages psychological safety by ensuring employees feel comfortable sharing ideas. Every suggestion receives attention, even when it cannot be implemented. As he explains, “Nobody steals ideas.” He further reinforces participation by reminding employees, “The worst thing that’s gonna happen is we’re going to say no, because we’ve tried it already.” Warehouse Leadership Creates a Culture People Want to Join Maintaining morale becomes even more challenging during periods of extraordinary growth. Avery believes transparency and recognition make the difference. Before LesserEvil entered its busiest shipping month ever, leadership openly communicated what employees should expect and invited them to help develop solutions. The approach worked. Employees immediately proposed staging inventory differently, improving workflows, and preparing for increased volume. After the company’s busiest shipping day, Avery recognized employees throughout the organization, prompting praise from executives and colleagues alike. As he notes, “It’s hard to be in a bad mood when people that you don’t see every day are cheering you on.” Avery views technology as something that enhances employee success rather than replaces it. He reminds leaders that “Nobody knows more about loading the trucks than the guys loading the trucks.” By combining frontline expertise with new technology, LesserEvil continues to find better ways to operate while preserving the culture that fueled its success. Key Takeaways Psychological safety encourages continuous innovation and collaboration. Company-wide recognition reinforces employee engagement during demanding periods. AI tools are encouraged to improve communication, idea generation, and employee development. Technology decisions involve frontline employees who best understand warehouse operations.

The post Warehouse Leadership Lessons from LesserEvil appeared first on Material Handling Wholesaler.

Retina Robotics Brings Computer Vision to Warehousing

Mon, 29 Jun 2026 15:10:23 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin speaks with Maanav Iyengar, Co-Founder and CEO of Retina Robotics. Founded by robotics engineers with firsthand exposure to warehouse operations, Retina Robotics makes automation more accessible through computer vision. In this conversation, Iyengar discusses the challenges slowing automation adoption, how Retina Robotics is helping warehouses improve inventory accuracy, and why the company believes computer vision can transform inventory management. Making Automation Accessible to More Warehouses Retina Robotics was founded after Iyengar and his co-founder (Vishrut Bohara) spent months speaking with warehouse operators and managers. As Iyengar explained, “We wanted to answer the question, which was why it is that autonomy is not being broadly adopted at a scale that people have expected it to.” Through those conversations, the team discovered, “over 80% of the warehouses in the US have basically zero automation and are still largely manual.” According to Iyengar, “We were yet to see a single solution that could manage all types of inventory, all types of operations, such that the end consumer wasn’t changing their warehouse drastically or spending an arm and a leg for a wide array of solutions.” That insight led Retina Robotics to develop WAM, a computer vision device that mounts directly onto forklifts, order pickers, reach trucks, and other equipment already operating within the warehouse. Preventing Errors Before They Happen Many inventory systems identify mistakes after they occur. Retina Robotics takes a different approach. The WAM actively communicates with operators during picking and put-away activities to help prevent errors before they impact operations or customers. Iyengar explained the company’s philosophy, stating, “I don’t think it’s enough to tell somebody that they have made a mistake. I think we must correct that mistake from happening before it could even happen.” The system validates inventory movements in real time and can notify operators when they select the wrong pallet or attempt to place inventory in the wrong location. As Iyengar described it, “what we wanted to do was build a solution that would actually stop you from picking the wrong item before you could even pick it up, or stop you from putting an item away in the wrong spot.” In addition to validation, WAM captures dimensions, occupancy data, and images throughout the inventory lifecycle. The long-term vision is even bigger. Iyengar noted that “what we are building toward is a truly hands-free scanless future.” Real-Time Pallet Tracking with WAM™ Turning Everyday Operations into Continuous Audits Using WAM, operators can collect inventory data as they drive through the facility. As Iyengar explained, “Just by driving past an aisle as you normally would, doing your routine work like picking or putting away, not changing the way that you do anything, we are not trying to disrupt your aisle. WAM will continuously and fully passively audit and cycle count all of your inventory.” This approach has delivered measurable results for customers. One operation uses WAM to track pallet locations and eliminate time spent searching for inventory. Another uses the system to audit inventory in very narrow aisles where traditional solutions struggle to operate. According to Iyengar, “we’ve saved them hundreds of thousands to even potentially, you know, million plus dollars in lost inventory.” Looking ahead, Retina Robotics is expanding its capabilities into case-level inventory management, an area the company believes remains underserved across the industry. Continuous Drive By Auditing with WAM™ Key Takeaways from Retina Robotics More than 80% of U.S. warehouses remain largely manual. Retina Robotics developed WAM after interviewing warehouse operators about automation challenges. WAM mounts directly onto existing forklifts, reach trucks, order pickers, and other MHE. The system scans, counts, dimensions, tracks, and validates inventory using computer vision. All processing occurs on-device, reducing dependence on warehouse Wi-Fi connectivity. WAM helps prevent fulfillment errors before inventory leaves the facility. The New Warehouse Podcast Retina Robotics Brings Computer Vision to Warehousing

The post Retina Robotics Brings Computer Vision to Warehousing appeared first on Material Handling Wholesaler.

RFID Delivers Real-Time Package Intelligence for UPS

Mon, 29 Jun 2026 14:57:55 +0000

Welcome to this episode of The New Warehouse Podcast. At Supply Chain Point 2026, Kevin spoke with Jon Bell, of UPS’s Advanced Technology Group, and Darryl Forbes, Vice President of Operational Technology at UPS. UPS delivers millions of packages every day, making visibility, reliability, and customer experience critical to success. In this conversation, Bell and Forbes discuss how UPS is leveraging RFID technology to move beyond traditional package tracking and create what they describe as a smarter, more connected network. The discussion explores how RFID is improving visibility, reducing misloads, creating new customer touchpoints, and laying the foundation for predictive supply chain operations powered by real-time data. UPS Moves from Package Tracking to Package Precision RFID has existed for decades, but UPS believes the technology has finally reached a tipping point. Costs have fallen, capabilities have improved, and the value extends far beyond simply knowing where a package is located. Bell explained that RFID provides customers with unprecedented visibility while helping UPS achieve new milestones throughout the package’s journey. The company views RFID as a foundational shift in how packages move through its network. As Bell noted, “As we transition from a scanning-based network to a sense and respond-based network, we are going to be sensing more packages versus scanning them.” The operational impact is already measurable. Bell shared that UPS has decreased misloads nearly 70% by identifying packages placed on the wrong vehicle before they leave the facility. Closing the Visibility Gap For many shippers and consumers, one of the most frustrating parts of parcel delivery is the period between “Label Created” and the first carrier scan. During that window, there is often little indication that a package has actually entered the transportation network. UPS recognized that challenge early in its RFID initiative. As Forbes explained, “We knew that we had to tie the customer into that. So that’s what really unlocked our ability to get the program started.” Using RFID-enabled printers and smart pickup equipment, UPS can now create a new visibility milestone before a package reaches a sorting facility. Forbes explained that “When that vehicle breaks the geo-fence, we create a new event called pickup.” That additional scan confirms that UPS has taken possession of the shipment and provides customers with a level of visibility that previously did not exist. The company is also expanding visibility events throughout its network, including loading, unloading, and exception management. The rollout is already operating at significant scale. According to Forbes, 5,500 The UPS Store locations are fully RFID-enabled and UPS has been onboarding both enterprise and SMB customers. The response has been overwhelmingly positive. Forbes noted that “Our customers have shown an extreme amount of interest in what we’re doing” because RFID creates “fantastic new touch points that they’ve never seen before.” Rather than changing how customers consume shipment information, UPS is enhancing existing visibility platforms with richer data and more meaningful milestones. The Future Is Data-Driven Supply Chains The most compelling part of UPS’s RFID strategy isn’t RFID. It’s the data. While most discussions focus on tracking packages, UPS sees RFID as the foundation for a more intelligent and predictive supply chain. As Bell explained, “The RFID chip is nothing more than a data vessel.” The real value comes from transforming that information into actionable insights. He emphasized this point by stating, “the people who are gonna win are the people that take that data and start doing decision-making with that data.” UPS is already feeding RFID-generated data back to customers through APIs, visibility platforms, and shipment tracking systems. Looking ahead, Bell believes the industry is moving toward a future where supply chain events become increasingly predictable. He stated, “With enough data in the right format, everything in the supply chain becomes predictable.” Key Takeaways from UPS RFID eliminates the gap between “Label Created” and package pickup. UPS has already enabled RFID across 5,500 The UPS Store locations in the U.S. SMB and enterprise customers are actively using the technology. RFID-generated data is being delivered through existing customer visibility platforms. UPS views RFID as the foundation for predictive supply chain operations. UPS believes better data will lead to more reliable and predictable supply chains. The New Warehouse Podcast RFID Delivers Real-Time Package Intelligence for UPS

The post RFID Delivers Real-Time Package Intelligence for UPS appeared first on Material Handling Wholesaler.

Warehouse Innovation Starts with Solving Problems

Mon, 22 Jun 2026 12:43:53 +0000

Welcome to The New Warehouse Podcast. In this episode, Kevin speaks with Blair Healey, Supply Chain Implementation Manager at Sonepar US, Cam Dore, Director of Operational Innovation at US Electrical Services (USESI), and Chris Shannon, who oversees distribution center and transportation operations for USESI. Recorded at the Kardex Experience Lab in Cincinnati, the conversation explores how leading distributors are approaching warehouse innovation through automation and AI. The discussion highlights the role of technologies in service levels, increasing capacity, and helping warehouse teams become more proactive and efficient. Warehouse Innovation Begins with Better Processes For both Sonepar and USESI, innovation starts long before automation equipment is installed. As customer expectations continue to evolve, distributors are looking for solutions that can adapt alongside them. Healey noted that “our customer expectations are changing, and they’re continuing to change at a quicker pace as customers are using AI as well.” He also highlighted how AI can serve as a support system for employees, explaining that “it’s kind of a sparring partner, with the team and allows your team to do more than they were doing on their own.” That mindset extends to automation investments like AutoStore. Sonepar’s approach focuses on long-term scalability, enabling facilities to increase capacity, offer more products, and improve service levels without increasing building footprints. Automation Creates Competitive Advantages Dore explained that AutoStore allows USESI to process orders later in the day while still meeting demanding delivery requirements. He noted that many customers operate on tight timelines and may place critical orders late in the evening for next-morning delivery. By automating portions of the fulfillment process, the company can respond more effectively to those requests. Shannon emphasized that automation is not about reducing headcount. Instead, it helps organizations increase capacity and improve service levels. As he explained, “This allows us to double our capacity, et cetera, with the same staff we have.” He further reinforced the company’s philosophy toward technology adoption, stating, “So it’s not about losing jobs. It’s about how you leverage stuff.” The discussion also touched on emerging capabilities such as robotic picking and AI-enabled bin induction. These tools can help consolidate orders, reduce manual effort, and create additional operational flexibility while allowing employees to focus on higher-value work. AI Adoption Requires Leadership and Real Use Cases USESI uses AI tools such as Replit and Claude to create applications that solve everyday operational challenges. Examples include slotting improvements and customer-facing delivery visibility tools. One internally developed application allows employees and customers to track deliveries in real time, providing immediate value across the organization. According to Shannon, leaders should focus on solving meaningful business problems first. He explained, “If I don’t say anything else and anybody gets anything from me, it’s understanding a real problem.” That philosophy has helped drive broader adoption throughout the company. Today, more than 25 employees across a 2,500-person organization are actively using AI-powered tools. For Dore, leadership advocacy has been critical. AI applications are helping supervisors move from reactive management to proactive decision-making. As he explained, “being able to create tools, quickly, cheaply, that allow our supervisors to see proactively, where we’re struggling in a building, really just unlocks potential to improve before there’s a fire drill.” The result is an organization that uses innovation not as a technology initiative, but as a business strategy. Key Takeaways Sonepar and USESI view warehouse innovation as a combination of automation, AI, and process improvement. AutoStore provides scalability without requiring building expansion. Later order cut-off times help distributors improve customer service levels. USESI uses AI tools such as Replit and Claude to develop custom operational applications. One internally developed application provides real-time delivery visibility for customers and employees. Automation enables higher throughput while maintaining existing staffing levels. AI is being used to reduce administrative work and increase employee productivity. The New Warehouse Podcast Warehouse Innovation Starts with Solving Problems

The post Warehouse Innovation Starts with Solving Problems appeared first on Material Handling Wholesaler.

Global Industrial: Warehouse Automation Solutions for Suppliers and Operators

Thu, 18 Jun 2026 13:51:31 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin chats with Steven Leeds, Senior Category Manager at Global Industrial. Global Industrial supplies more than 1.6 million products to warehouses, distribution centers, manufacturers, and other industries across North America. As both a supplier and warehouse operator, the company brings a unique perspective to the challenges facing the industry. For Global Industrial, Automation Solutions Start with Real Problems Global Industrial’s perspective on automation is shaped by experience. The company operates five distribution centers in the United States and two in Canada, giving it firsthand knowledge of warehouse challenges. According to Leeds, many of the issues their customers face are the same ones they encounter themselves. Leeds noted that “what I hear from customers a lot is that they need to do more with less.” That dilemma is driving interest in automation, but not necessarily in large-scale facility transformations. Instead, Global Industrial is seeing a more targeted approach. As he explained, “we’re seeing more targeted integrations of automation. It’s not just, ‘Hey, automate my entire facility.’” Balancing Efficiency, Safety, and Employee Experience Leeds emphasized that warehouse leaders continue to prioritize workplace safety and ergonomics as labor markets remain competitive. He explained that “the top thing that’s spoken about in our warehouse, and I believe should be the same for all other warehouses, is really worker safety and ergonomics.” Those concerns influence how Global Industrial develops and evaluates products for warehouse environments. One example is the company’s autonomous stretch wrap machine. For instance, manual pallet wrapping can strain workers’ backs and shoulders and produce inconsistent results. Not to mention, make you dizzy. However, an automated solution can wrap a pallet in approximately 70 seconds, operate for an entire shift on a single battery charge, and process up to 250 pallets before recharging. Beyond productivity gains, Leeds sees automation as a retention tool. He observed that “Nowadays, someone can go pay an extra dollar, and steal your entire workforce.” As a result, investments that improve employee comfort and reduce repetitive tasks can help create a more attractive workplace while supporting operational goals. The Future of Automation Is Collaboration One of the most interesting themes is the growing interest in technologies that eliminate tedious work, allowing employees to focus on higher-value activities. Leeds pointed to autonomous floor scrubbers as an example. One manufacturer operating a three-million-square-foot facility implemented automation not across the entire operation, but specifically for walkway cleaning. The goal was simple: free employees to focus on more impactful work. That experience led to a key realization. As Leeds explained, “it’s not about a total solution.” Instead, “it’s about identifying key issues, key problems, and then seeing if an autonomous machine can address them.” Looking ahead, Leeds expects automation adoption to continue growing as costs decline and technology becomes more accessible. Key Takeaways Global Industrial serves warehouses, distribution centers, manufacturers, healthcare, hospitality, and education markets. The company offers approximately 1.6 million products. Global Industrial operates 5 U.S. distribution centers and 2 Canadian distribution centers. Autonomous stretch wrappers can wrap a pallet in approximately 70 seconds. Autonomous floor scrubbers can be programmed to clean specific areas and return to docking stations automatically. One customer used automation to clean walkways in a 3-million-square-foot facility. The New Warehouse Podcast Global Industrial: Warehouse Automation Solutions for Suppliers and Operators

The post Global Industrial: Warehouse Automation Solutions for Suppliers and Operators appeared first on Material Handling Wholesaler.

3PL Customer Service Sets Great Providers Apart: Loki 3PL

Mon, 15 Jun 2026 13:48:35 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin chats with Rodney Galeano, Founder and CEO of Loki 3PL. Loki 3PL helps importers distribute and fulfill products across the United States, supporting both B2B and e-commerce operations. Since launching the company just a year and a half ago, Rodney has grown the business into a new 100,000-square-foot facility in East Brunswick, New Jersey. In this conversation, he shares down-to-earth lessons from scaling a 3PL, what brands should look for in a logistics partner, and why customer service remains the most important differentiator in a crowded market. Choosing a 3PL Is About More Than Price. For many brands, as Rodney explained, “A decision of which 3PL you use is a big one.” Instead of just comparing rates, brands should evaluate leadership, operational experience, warehouse processes, reporting capabilities, and accountability measures. He encouraged brands to look beyond sales presentations and ask tough questions when choosing a 3PL. What do the warehouse operations look like? What are the company’s standard operating procedures? How are mistakes handled? He also stressed the importance of clear agreements. According to Rodney, “The brand should be able to hold the 3PL fully accountable.” That includes defining responsibilities for lost inventory, damaged products, and misshipments, as well as reporting expectations and performance metrics. Why Smaller 3PLs Still Have an Advantage As larger providers continue to expand their logistics offerings, many brands are evaluating whether to work with global operators or smaller regional providers. Rodney believes owner-operated 3PLs still offer meaningful advantages. He noted, “I think there is a niche for the smaller 3PLs.” Unlike larger organizations, smaller providers often offer direct access to decision-makers and greater operational flexibility. Rodney highlighted that “a smaller 3PL does things that the bigger one will not.” He pointed to examples such as relabeling thousands of units, handling product recalls, opening warehouses on weekends, and supporting urgent customer requests. He also believes responsiveness matters. During the discussion, he repeatedly emphasized the importance of answering calls, solving problems quickly, and being available when customers need help. For growing brands, that flexibility can become a significant competitive advantage when supply chain disruptions or unexpected issues arise. 3PL Customer Service, Communication, and Accountability Drive Success While warehouse space and technology are important, Rodney repeatedly returned to one theme: service. Loki recently expanded into a 100,000-square-foot facility after outgrowing two smaller warehouses. The company plans to continue growing, but Rodney believes customer service will remain the foundation of that growth. He stated, “If they’re looking for service, reliability, strong leadership, and the best communication, Loki’s a wonderful option.” He also emphasized transparency. As Rodney explained, “We make mistakes, we own up to them. We communicate, we’re transparent, and then we do something about it.” Rather than hiding problems, he believes successful partnerships are built on honesty, accountability, and continuous improvement. Ultimately, Rodney’s philosophy is simple. “It’s the service. It’s everything.” Key Takeaways Loki 3PL has grown into a 100,000-square-foot warehouse after just 18 months in business. The company supports both B2B fulfillment and direct-to-consumer e-commerce operations. Rodney recommends evaluating SOPs, reporting capabilities, and accountability measures when selecting a 3PL. Brands should establish detailed agreements that clearly define responsibilities and performance expectations. Smaller owner-operated 3PLs can provide greater flexibility and direct access to decision-makers. Customer service, responsiveness, and communication are core differentiators in the 3PL industry. The New Warehouse Podcast 3PL Customer Service Sets Great Providers Apart: Loki 3PL

The post 3PL Customer Service Sets Great Providers Apart: Loki 3PL appeared first on Material Handling Wholesaler.

Using Supply Chain Technology to Drive Operational Excellence

Wed, 10 Jun 2026 18:55:51 +0000

Southern Glazer’s Wine & Spirits is the world’s largest wine and spirits wholesaler, serving 47 markets across the United States, Canada, and beyond. For this episode of The New Warehouse Podcast, Kevin mixes it up with Karli Sage, Vice President of Supply Chain Management Technology and Engineering at Southern Glazer’s Wine & Spirits. Together, they discuss how to approach warehouse technology and automation to improve inventory visibility. The discussion highlights the unique challenges of managing thousands of SKUs, maintaining inventory accuracy, and scaling innovation across a complex distribution network. Why One-Size-Fits-All Automation Falls Short Warehouse inventory management looks very different in the wine and spirits industry. As Karli explains, “We have about 17,000 and counting, the different types of SKUs. So it’s very complex.” That level of variety creates challenges that many automation providers have never encountered. “If you’re distributing paper towels, paper goods, or products outside of wine and spirits, it’s difficult for us to determine whether a solution is truly apples-to-apples with our operation.” She adds, “As technology across the supply chain continues to evolve, it becomes increasingly challenging to identify what will actually be effective for our business. That’s one of the biggest changes I’ve seen over the last few years.” Karli warns against blindly following industry trends, stating that “The shiny object syndrome is a real disease.” Instead, her team focuses on solutions that fit the realities of the unique needs of the wine and spirits industry. Using Autonomous Drones to Improve Inventory Visibility Southern Glazer’s turned to Corvus Robotics because of its ability to operate autonomously and integrate directly with warehouse management systems. According to Karli, the results have been significant. “We’ve been able to speed up the process because what takes someone a few minutes to do, we can now get done in a couple of seconds. She adds, “We can count almost every warehouse within two weeks.” The company has also identified approximately 30,000 inventory opportunities across facilities where drones have been deployed. “ We are no longer shorting products. We are giving them everything that they ordered because we have better visibility.” Combining Automation with Human Expertise Southern Glazer’s does not view automation as a workforce reduction strategy. Instead, the company focuses on redirecting employees toward higher-value activities. Karli believes successful automation projects require clear communication and a well-defined purpose. She explains that “Inventory is dollars. It’s money. It’s what you own.” Helping employees understand the business impact of inventory accuracy became a critical part of the change management process. The company also emphasized employee development. Karli explains that automation creates growth opportunities, saying, “This allows us to take those individuals and put them into that stretch project that proves to them we see you, and we see what you’re capable of and what you can do.” By pairing technology investments with workforce development, Southern Glazer’s has improved inventory visibility while strengthening employee engagement and operational performance. Key Takeaways Autonomous drones reduced the time required to perform wall-to-wall inventory counts. Facilities can now count nearly every reserve location within two weeks. Drone deployments have identified roughly 30,000 inventory opportunities. Improved inventory visibility helps reduce shortages and improve customer service. Southern Glazer’s redeployed cycle counters into higher-value inventory and quality-focused activities. The New Warehouse Podcast Using Supply Chain Technology to Drive Operational Excellence

The post Using Supply Chain Technology to Drive Operational Excellence appeared first on Material Handling Wholesaler.

Dexory Storage Health: Benefits Beyond Inventory Accuracy

Mon, 08 Jun 2026 13:29:24 +0000

In this episode of The New Warehouse Podcast, Kevin speaks with Matthew Smith, Senior Product Manager at Dexory. Dexory is a warehouse intelligence platform that combines autonomous robotics and software to help warehouses improve visibility across their operations. The conversation focuses on Dexory Storage Health, which recently earned Best New Innovation recognition at MODEX. Warehouse Visibility Starts with Better Data Dexory goes to great heights to continuously scan warehouse locations and collect operational data. However, Smith emphasizes that the robot itself is only part of the solution. As he explains, “The hardware involved on the platform is a glorified data collection tool.” The real value comes from transforming that data into actionable intelligence. Dexory’s platform combines robotics, cameras, sensors, and warehouse data to help operators identify discrepancies and gain deeper visibility into inventory and storage conditions. Smith notes that warehouses can remotely inspect locations and verify information without lengthy walks through large facilities. He explains that “most of the customer experience and certainly the value sits in the insights.” The system can scan large operations, including warehouses with up to 100,000 storage locations. Expanding Visibility Beyond Inventory Accuracy Dexory Storage Health came to fruition after customers identified a visibility gap that extended beyond inventory accuracy. Warehouses knew where and how much, but many lacked a reliable way to monitor storage conditions. Smith explains, “We knew that there was a gap in terms of our offering and what the market was providing in terms of ensuring stock and the location housing that stock was in the right condition.” Through customer conversations, Dexory discovered recurring concerns related to damaged pallets, damaged racking, crushed cases, hanging shrink wrap, tipping products, and empty pallet locations. Today, Dexory Storage Health can automatically detect those conditions across warehouse operations. The platform identifies issues that could impact safety, compliance, quality assurance, and operational efficiency. The system can also support future use cases such as slotting compliance, fire-spread mitigation, and warehouse-specific operating rules. According to Smith, “The origins of this area, this kind of feature set really came through customer conversations.” Those discussions continue to shape the product roadmap as customers identify new opportunities to improve visibility. Turning Visibility Into Action with Dexory Storage Health Visibility alone does not create value. Warehouses must be able to act on the information they receive. That principle has become a major focus for Dexory Storage Health. Early customer feedback has been encouraging. Smith says, “Customers are broadly reporting they are detecting more cases to remediate and to fix.” Because robots scan facilities daily, operators can identify problems faster and address them before they create larger operational issues. The impact extends beyond issue detection. Smith notes that some customers are seeing positive changes in workforce behavior as accountability improves. He explains that “warehouse teams know that they’re even more accountable for being prudent” when facilities are monitored consistently and comprehensively. Key Takeaways Dexory Storage Health detects damaged racking, damaged pallets, tipping items, crushed cases, hanging shrink wrap, and empty pallet locations. Dexory’s robots can support facilities with up to 100,000 storage locations. Customer demand directly influenced the development of Storage Health. Customers report finding operational issues they previously did not know existed. Daily warehouse scans help reduce time-to-detection for safety and quality concerns. Some customers are reporting positive workforce accountability and behavioral improvements. The New Warehouse Podcast Dexory Storage Health: Benefits Beyond Inventory Accuracy

The post Dexory Storage Health: Benefits Beyond Inventory Accuracy appeared first on Material Handling Wholesaler.

Warehouse Automation Infrastructure Beyond the Robots

Mon, 08 Jun 2026 12:58:02 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin Lawton speaks with Jonathan Miles of Nucor Warehouse Systems live from MODEX 2026. Nucor Warehouse Systems designs, fabricates, and supplies warehouse racking systems, ASRS solutions, rack-supported buildings, and other engineered storage infrastructure that support modern distribution operations. Miles shares how Nucor is investing in automation while supporting customers with engineered warehouse solutions. The discussion also highlights Nucor’s vertically integrated steel production model and the growing importance of recycled steel in the supply chain. Automation Growth Starts with Infrastructure Automation may dominate conversations at MODEX, but the systems that support it remain critical to long-term warehouse performance. Miles explains that demand for automated storage and retrieval systems continues to rise as companies look for greater consistency, scalability, and operational efficiency. As Miles states, “I would say there’s an uptick in demand in automated storage and retrieval systems.” Nucor Warehouse Systems supports those projects through racking systems, rack-supported buildings, and engineered warehouse solutions. The company is also expanding its engineering capabilities to support customers earlier in the design process. Miles explains, “We want to provide more engineered solutions to the market. We’re building up a strong engineering team and design team to take some of those resources in-house and offer better solutions to end users.” That investment extends internally as well. Nucor is adding 425,000 square feet of automated capacity at a new facility in Georgia. Safety remains a major driver behind that investment. Miles shares, “Any opportunity to remove a teammate’s hands from material is gonna help us on that journey to, you know, no recordables in our facilities.” Cold Storage Automation Continues to Expand Cold storage and refrigerated warehousing remain major growth areas for warehouse automation. According to Miles, automation has become deeply integrated within refrigerated environments due to labor demands and operational complexity. He explains, “Refrigeration really is almost all automated.” The discussion highlights how automated guided vehicles, shuttle systems, and rack-supported insulated panel systems are becoming standard in refrigerated facilities. Nucor showcased insulated panel solutions mounted directly on racking systems at MODEX to demonstrate how warehouse infrastructure and automation increasingly work together. Miles also notes that food and beverage remains a stable investment area for operators. As he explains, “Food and beverage is a pretty solid spend every year from an end user perspective.” Sustainability Remains Part of the Supply Chain Story Sustainability has become a larger part of warehouse investment decisions, especially among enterprise customers seeking supply chain visibility. Nucor’s vertically integrated steel production model gives the company a unique position in that conversation. Miles explains, “One of the big differences with Nucor is we’re vertically integrated. So we recycle about 20 million tons of steel a year.” The company produces approximately 25 million tons of steel annually, much of it sourced from recycled materials such as scrap vehicles and appliances. Miles explains, “We’re able to tell a sustainability story because we know exactly where that scrap came from.” The sustainability discussion also ties directly to the longevity of warehouse infrastructure. As Miles puts it, “Steel is almost endlessly recyclable.” Key Takeaways Nucor Warehouse Systems is adding 425,000 square feet of automated capacity at its new Georgia facility Automated storage and retrieval systems continue to see increased demand across warehousing operations Safety is a major automation driver, especially for reducing hand injuries during material handling Refrigerated warehousing has become heavily automated with AGVs and shuttle systems Food and beverage remains a consistent investment area for warehouse automation The New Warehouse Podcast Warehouse Automation Infrastructure Beyond the Robots

The post Warehouse Automation Infrastructure Beyond the Robots appeared first on Material Handling Wholesaler.

Warehouse Fulfillment Automation Built for Throughput

Wed, 03 Jun 2026 20:14:29 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin Lawton speaks with David Scheffrahn live from MODEX 2026 in Atlanta. Representing Ocado Intelligent Automation(OIA), Scheffrahn shares how the company is combining high-density storage, robotic fulfillment, AI-driven orchestration, and autonomous mobile robots to improve warehouse fulfillment automation. The conversation explores Ocado’s storage and retrieval system, its fulfillment software platform Ocado IQ, and a new AMR focused on pallet and case fulfillment. High-Density Warehouse Fulfillment Automation Ocado’s fulfillment system focuses heavily on maximizing warehouse density and throughput. The company’s tote-based storage and retrieval system uses robots that move across the top of a grid to retrieve inventory and fulfill orders with minimal human intervention. Scheffrahn explains that the system is already operating at a significant scale, noting, “In fact, we do approximately 5 million picks a week, right now with these robots.” Rather than emphasizing aesthetics, Ocado’s robots are engineered to reduce weight and improve performance. As Scheffrahn explains, “Every design decision that we’re making is about throughput.” He adds, “Light robots mean they can accelerate faster. It means we can have more robots on the grid because they’re lighter.” That same thinking extends into warehouse cube utilization. While the MODEX demo displayed a smaller version of the system, Scheffrahn explained that production deployments can scale significantly higher. “Normally we do 21 totes high,” he says, allowing operators to “cube out an entire warehouse.” Warehouse Automation Planning: When to Start Thinking About AMRs AI and Resiliency Drive Fulfillment Decisions Scheffrahn explains, “There’s a massive AI component to figuring out what to pick, where to place it, where to stage it.” The robotic picking process also relies heavily on machine learning and operational feedback loops. Ocado continuously evaluates which items robots handle effectively and which should remain human-assisted. Scheffrahn describes the process by saying, “Our goal is to have a larger percentage of the items in the grid to be able to be picked by the robot.” Resiliency is another major focus. The system reroutes workflows when issues occur, reducing operational disruption automatically. That resiliency mindset even impacts battery management. Instead of parking robots to recharge, Ocado uses another robot to swap batteries in roughly 30 seconds. Ocado IQ Connects Warehouse Fulfillment Automation The second half of the conversation shifts toward Ocado IQ, the company’s fulfillment execution software platform. The software sits below the WMS layer and coordinates workflows across Ocado’s autonomous mobile robots, including Chuck and the newly introduced Porter. Scheffrahn explains, “It’s our software that creates the most efficient fulfillment strategy for that.” While Chuck focuses on individual-item fulfillment, Porter supports mixed-pallet and case-fulfillment workflows. Porter also addresses one of the more difficult AMR challenges in warehousing: handling empty or lightweight pallets. Scheffrahn explains, “Porter’s got a really unique fork design where it actually pulls up to the pallet, it extends true forks into the pallet, picks it up, and then places it on the AMR.” He notes, “They work in the same operation, in the same workflow.” Key Takeaways Ocado’s storage and retrieval system currently supports approximately 5 million robotic picks per week. The company’s fulfillment system can scale up to 21 totes high to maximize warehouse cube utilization. Ocado’s robots are 3D printed to reduce weight, improve acceleration, and extend battery life. AI continuously determines which items should be robot-picked versus human-picked Porter specifically improves the handling of lightweight and empty pallets. Goods-to-person pallet fulfillment workflows are gaining traction in omnichannel operations. The New Warehouse Podcast Warehouse Fulfillment Automation Built for Throughput

The post Warehouse Fulfillment Automation Built for Throughput appeared first on Material Handling Wholesaler.

Material Flow Optimization from K.Hartwall

Mon, 01 Jun 2026 14:34:02 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin Lawton speaks with Courtney Jackson live from the MODEX 2026 show floor in Atlanta. Courtney shares how K. Hartwall approaches material flow optimization through connected cart systems, tugger trains, and its LiftLiner solution. From ergonomics and e-commerce picking to AGV integration and ROI analysis, Courtney explains how flexible cart-based systems can help warehouses optimize movement throughout the supply chain. Material Flow Optimization Starts with Movement Hartwall’s approach centers on improving the flow of products through a facility. Courtney explains that the company’s solutions are designed to work together rather than function as isolated tools. As she explains, “What we do is really focus on material flow, with our customers.” She also notes that the systems are designed to “improve our customers’ flow, improve safety, improve efficiencies throughout the entire supply chain.” The discussion also highlighted common warehouse bottlenecks. According to Courtney, many operations are still trying to solve issues related to picking speed, accuracy, and safety. She says customers are often asking, “How can we move more product but still safely in one move?” Instead of relying solely on traditional pallet and forklift workflows, K. Hartwall positions its carts as a more flexible option. Courtney explains, “Our carts are meant to sometimes serve as an alternative to pallets, to forklifts to move just a little bit more seamlessly in an operation.” LiftLiner Systems Improve Efficiency and Safety A major focus of the conversation was K. Hartwall’s LiftLiner tugger train system. The solution allows operators to transport multiple carts or pallets simultaneously while reducing travel time across the warehouse. Courtney describes the LiftLiner as “a wonderful and unique system.” She adds, “This gives you or operators the ability to do more with less.” The material flow optimization gains become even more significant at scale. Courtney explains, “You’re able to move up to eight pallets or eight row carts in one move.” She continues by saying the system helps operations by “eliminating unnecessary travel and decreasing travel time within your warehouse.” Courtney explains the flexibility of the cart system to improve workflow efficiency. As she puts it, “That does speed up the picking process when you’re able to go, you pick from both sides.” Automation and E-Commerce Drive New Use Cases Courtney confirmed that AGVs and AMRs can work directly with the LifetLiner system. She explains, “For those companies that do have those, AGVs that can connect seamlessly to our lift liner.” She also notes, “You don’t need an operator anymore.” E-commerce fulfillment operations may see particularly strong benefits from these workflows. Courtney discussed how large facilities often lose time through long travel distances during picking operations. She explains that in major warehouses, workers may travel significant distances during fulfillment. According to Courtney, “This right here decreases the time that you’re picking by, in a significant way.” Hartwall also works closely with customers to evaluate workflows before recommending a solution. Courtney explains, “I’m getting on-site with the customers. I’m really getting an understanding of their entire process from inbound to outbound, what they’re picking, how they’re picking.” She adds that the company supports decisions with data-driven evaluations and ROI analysis to help optimize future operations. Key Takeaways on Material Flow Optimization K. Hartwall focuses heavily on material flow optimization across the supply chain The LiftLiner system can move up to eight pallets or carts in one trip Tugger train systems help reduce unnecessary operator travel time Cart-based workflows can serve as alternatives to traditional forklift movement The LiftLiner supports ergonomic picking from both sides of the cart AGVs and AMRs can integrate directly with the LiftLiner system

The post Material Flow Optimization from K.Hartwall appeared first on Material Handling Wholesaler.

Autonomous Yard Operations from YMX Logistics

Mon, 01 Jun 2026 13:14:04 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin Lawton speaks with Rock Stars Matt Yearling and Erin Mitchell of YMX Logistics, and industry analyst Bart De Muynck, live from MODEX 2026. The discussion covers technology enablement, autonomous yard operations, digital twins, safety culture, and the growing need for orchestration across the yard. The episode also highlights how YMX combines operational expertise with technology to help shippers create more value from an area many organizations still underestimate. Yard Operations Are Becoming a Strategic Priority For years, many warehouse operations viewed the yard as a secondary concern. However, that perspective is beginning to shift as distribution centers push for greater throughput and faster execution. Matt Yearling explains that yard operations now sit at the center of a larger operational challenge. As he notes, “There’s nobody on the planet that looks at the yard as a specific problem.” He adds, “It is between transportation and warehousing.” That middle ground has become increasingly important as warehouse and transportation systems improve. According to Bart De Muynck, many companies optimized transportation and warehouse execution first, which exposed inefficiencies in the yard. He explains, “We’ve optimized that. We’ve created a lot more velocity. Now the yard has become an even bigger bottleneck.” Delays in the yard can disrupt dock scheduling, labor planning, outbound fulfillment, and customer service. De Muynck compares the issue to a minor mechanical failure that stops an expensive car. As he puts it, “It’s not always the cost of something, but it’s the impact it has on your operation.” Technology Alone Does Not Solve the Problem YMX’s approach focuses on combining operations, technology, and execution rather than simply deploying software. Yearling explains that traditional yard management systems only solve part of the challenge. Instead, YMX focuses on orchestrating the entire operation through modeling, planning, execution, and visibility. Yearling explains, “It’s very clear that it’s the convergence of operations and technology, focusing on what is the problem you’re trying to solve?” He continues, “It isn’t about — let’s go and hunt for the next widget and apply it and see whether or not it works.” The company’s latest announcement at MODEX further expands that philosophy. YMX discussed its capabilities for autonomous yard operations, including digital twins, computer vision, data capture, and autonomous trucks. However, Yearling emphasized that automation still requires operational expertise. He explains, “People think it does everything, and we know it does not.” Instead of adding more assets or labor to the problem, YMX uses operational data to model and optimize yard performance. Yearling says, “Show us some data. If you don’t have the data, we will observe, we will model it.” He also notes the company focuses on “delivering on doing more with less from day one.” Strong Yard Operations Still Depend on People While automation and orchestration played a major role in the discussion, Erin Mitchell highlighted the operational culture required to support large-scale yard operations. YMX operates across the country with drivers working around the clock, making communication and safety essential. Mitchell explains, “Our customer success is our success.” She adds, “We make sure that our drivers know that their job is to make the customer successful.” The company also uses technology to strengthen communication with drivers. YMX developed an always-on app that allows drivers to provide immediate operational and safety feedback. Mitchell explains, “Our entire leadership team reads all of those app comments.” She continues, “We get that feedback in real time.” YMX also places a strong focus on workforce development and diversity. Mitchell explains that the company invests heavily in training opportunities and leadership development. The organization also works to create more opportunities for women drivers and women in logistics roles. As yard operations become more advanced, YMX believes success will depend on combining technology with engaged people, operational discipline, and continuous feedback loops. Key Takeaways Yard operations are becoming a major operational bottleneck as warehouse and transportation systems improve. YMX views the yard as a strategic layer between transportation and warehousing Autonomous yard operations still require operational expertise and oversight. Digital twins, computer vision, and data capture help optimize yard performance. Real-time driver communication plays a major role in operational safety and culture. Leadership teams review driver feedback daily through YMX’s always-on communication tools. Workforce development and inclusion remain key priorities as YMX continues to grow. The yard may represent a smaller logistics spend, but it can create a significant downstream operational impact. The New Warehouse Podcast Autonomous Yard Operations from YMX Logistics

The post Autonomous Yard Operations from YMX Logistics appeared first on Material Handling Wholesaler.

Warehouse Execution Systems: Optimizing People, Processes, and Automation

Wed, 27 May 2026 14:20:00 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin Lawton speaks with Mike Krabbe and Suneel Krishnaswamy from enVista live at MODEX 2026. The three of them explore how warehouse execution systems (WES) are helping operations connect automation, labor, and workflows into a more synchronized operation. From digital twins and interoperability to robotic pallet building and pick-to-light systems, enVista shares how companies can scale automation without creating disconnected systems or operational bottlenecks. Why Warehouse Automation Needs Orchestration Automation has become far more accessible for third-party logistics and warehousing. However, adding more technology also creates more complexity across operations. That is where warehouse orchestration becomes critical. As Suneel Krishnaswamy explains, “Now with that, you need something, typically a WES, that optimizes across people, processes, and automation.” A WES sits between the WMS and WCS layers to coordinate workflows across labor, robots, AMRs, and automation systems. Krishnaswamy explains, “It’ll optimize and balance all of that to get maximum throughput for the warehouse.” The conversation also highlights why interoperability matters more than ever. Many facilities now use automation from multiple vendors. Without orchestration, operations can create choke points or disconnected workflows. Krishnaswamy notes, “Having that total flow through the warehouse and optimizing it so that all the different parts of the system work synchronously… that’s the part that WES will orchestrate.” Building Automation Roadmaps Without Starting Over One major takeaway from the discussion is that companies no longer need to pursue massive “rip and replace” automation projects. Instead, many are gradually implementing automation while preserving future flexibility. Krishnaswamy explains, “They want to do it in a very cautious and risk-averse way.” That cautious approach has increased the importance of a flexible WES layer. enVista’s approach allows companies to introduce automation step by step while maintaining consistent workflows. Krishnaswamy says, “It can give you a smooth ramp-up on automation once you have a good WES in place.” The pace of innovation also continues to accelerate across warehouse automation. Krishnaswamy notes, “Since about 2015, the automation scene drastically changed. And the pace of new innovation for automation has taken off.” That rapid innovation creates pressure for operators to remain adaptable. A strong orchestration layer helps warehouses evolve without becoming locked into outdated systems or infrastructure. Digital Twins, Visibility, and Real-Time Optimization enVista also showcased its digital twin and simulation capabilities during MODEX 2026. Krishnaswamy explains, “We can set it up and do a simulation with the customer’s order profile so they can actually see what to expect from that equipment for their profile.” That visibility becomes especially valuable during seasonal peaks or changing order profiles. Instead of guessing how automation will perform, operators can validate assumptions before investing. The discussion also covered enVista’s real-time digital twin capabilities. Krishnaswamy explains, “You don’t have to walk up to the floor and see what’s happening. You’ll be getting visibility right from wherever you are.” One standout feature of enVista’s pick-to-light solution is the removal of traditional mechanical buttons to reduce operator fatigue. Krishnaswamy explains, “There’s no mechanical movement there, which obviously gives a lot more durability to the lights, and more importantly, less fatigue for the operators.” Key Takeaways on Warehouse Execution Systems Warehouse automation is becoming affordable for smaller facilities, not just large operations. WES platforms help orchestrate labor, robots, AMRs, and automation into synchronized workflows Interoperability is critical as warehouses deploy automation from multiple vendors. A WES can help companies gradually scale automation without major operational disruption. Digital twins allow operators to simulate throughput and validate automation investments before deployment. Real-time visibility improves operational awareness and helps managers make proactive decisions. The New Warehouse Podcast Warehouse Execution Systems: Optimizing People, Processes, and Automation

The post Warehouse Execution Systems: Optimizing People, Processes, and Automation appeared first on Material Handling Wholesaler.

Warehouse Autonomy Meets Operational Reality

Tue, 26 May 2026 15:42:47 +0000

Welcome to this episode of The New Warehouse Podcast. Michael Lawrence, Director of Sales and Business Development from Anantak, shares a different approach to warehouse autonomy. Anantak has a deep focus on brownfield-friendly deployments, vehicle-to-vehicle interaction, and customer-driven engineering. The episode also highlights how Anantak’s technology navigates facilities without requiring major infrastructure changes inside warehouse operations. Why Warehouse Operations Fit Autonomy Anantak’s approach to automation intentionally focused on structured material-handling workflows rather than trying to force autonomy into unpredictable settings. “The material handling space is a really good one. It’s a well-defined environment with operational rules and expectations, which is a good fit for autonomy. It thrives with that kind of structure.” Regarding warehouse autonomy, companies can get caught up in flashy demos and big promises. Lawrence explained that Anantak took a more practical path from the beginning. “We didn’t want to just think that we could build the perfect widget and then we’d sell a million of them tomorrow.” As he put it, “It’s not just attaching a bunch of sensors and computers to existing industrial vehicles.” The goal is to make autonomy fit naturally into the customer’s operation. Autonomous Vehicles Built for Brownfield Facilities One of the biggest differentiators in Anantak’s approach is its ability to deploy inside existing facilities without requiring major operational changes. That stood out throughout the MODEX demonstration. Lawrence emphasized this directly when discussing customer concerns around deployment complexity. “A guiding philosophy for us is that we don’t impose ourselves on the customer environment.” He continued, “We don’t require any sort of infrastructure adjustment.” Instead, the system uses multiple LiDAR sensors, depth cameras, and internally generated “breadcrumbs” to navigate warehouse routes in real time. According to Lawrence, the platform processes data from five LiDARs, two safety LiDARs, and multiple cameras simultaneously. He explained, “We fuse all that in real time to navigate the vehicles in their environment.” The system also adapts dynamically to changing operational conditions. Lawrence described how the tugger behaves similarly to a roadway vehicle. “It follows its own lane. It thinks in terms of these, like, lanes on a road.” That flexibility allows the vehicles to function in brownfield warehouse environments while using the same routes operators already travel today. Vehicle-to-Vehicle Interaction Takes Center Stage MODEX was full of impressive demonstrations, but one rarely seen, if ever, was Anantak’s autonomous forklift and autonomous tugger, both actively interacting in real time. Lawrence explained the significance of the demonstration, saying, “We believe we are showing the first ever exhibit where two autonomous vehicles are actually interacting with each other.” Lawrence explained the broader impact on warehousing, “We can get the forklifts lifting and the tuggers tugging.” The roadmap already includes advanced stacking capabilities, additional customer-specific workflows, and collaboration. “One of our principles is engineering by experience.” He added, “We want the customer to tell us what is useful for them, and then we will build to that specification on our dime.” Key Takeaways on Warehouse Autonomy Anantak has been developing warehouse autonomy solutions for approximately 11 years. The company focuses heavily on brownfield warehouse environments without requiring infrastructure changes. The autonomous system does not rely on magnetic tape, QR codes, or wall markers for navigation. The platform processes data from five LiDARs, two safety LiDARs, and multiple depth cameras simultaneously. Anantak demonstrated coordinated interaction between an autonomous forklift and an autonomous tugger live at MODEX 2026. The tugger system navigates using internally generated “breadcrumbs” and lane-based movement logic. The company’s roadmap includes advanced stacking and additional autonomous forklift workflows. The New Warehouse Podcast Warehouse Autonomy Meets Operational Reality

The post Warehouse Autonomy Meets Operational Reality appeared first on Material Handling Wholesaler.