Podcasts Archives - Material Handling Wholesaler

Episode 612: Boosting warehouse productivity with Vecna Robotics

Wed, 30 Jul 2025 13:48:16 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Karl Iagnemma, CEO of Vecna Robotics. Vecna Robotics enhances warehouse productivity by integrating AI-driven autonomous robots with human workers, optimizing efficiency and safety. With extensive expertise in robotics and autonomous vehicle technology, Karl discusses his transition from developing autonomous vehicles for public roads to optimizing robotic solutions within warehouse environments. A particular focus of the discussion is Vecna’s innovative CaseFlow solution, a robotics-driven approach designed to significantly streamline the case picking process in warehouses, reducing manual labor and operational disruptions. Leveraging Autonomous Technology to Solve Case Picking Challenges Case picking, traditionally a manual and labor-intensive task, involves substantial physical effort and time inefficiency due to excessive walking. Vecna Robotics tackles this issue head-on with their CaseFlow solution, a fleet of automated pallet jacks coordinated seamlessly with human workers. Karl emphasizes, “We’ve seen essentially double productivity per worker—a 2X improvement—and we’ve reduced labor count by about 70%.” This system notably cuts down human travel time within warehouses, allowing workers to concentrate on the high-value task of building stable and secure pallets, thereby reducing employee fatigue and turnover. Effortless Integration into Brownfield Environments Recognizing that most facilities can’t afford massive disruptions or hefty capital investments, Vecna’s solution excels particularly in brownfield settings, existing warehouses without the luxury of redesigning operations from scratch. Karl points out the practicality and ease of adoption: “The world is brownfield. Most customers are not in a position to make multimillion-dollar investments.” Vecna’s solution requires minimal infrastructural adjustments, relying on intelligent software and wearables to guide human workers efficiently, ensuring a smooth, non-disruptive transition into automation. Why Software Drives Robotic Success While hardware is essential, Karl argues convincingly that software is the true differentiator in robotics. “So we’ve got great hardware, but the software is what really differentiates us. It’s what gives the robots the intelligence to perform very complex workflows.” Vecna’s AI-driven software allows robots to autonomously navigate, handle exceptions, and coordinate with each other and human operators efficiently. He states, “Software determines the capabilities and efficiency of the system. It’s 90% of the value.” Continuous software improvements lead to annual productivity increases of approximately 20%, far surpassing what human labor can achieve alone. This software-first approach results in significant long-term cost savings and efficiency gains for warehouse productivity. Key Takeaways on Warehouse Productivity Vecna’s CaseFlow system achieves double productivity per worker and reduces labor requirements by approximately 70%. Brownfield sites benefit significantly from Vecna’s low-disruption, software-integrated automation solutions. Software is crucial, driving 90% of the value by enhancing autonomous robot capabilities and system-wide efficiencies. Vecna’s software improvements yield an impressive annual warehouse productivity growth rate of around 20%. The New Warehouse Podcast Episode 612: Boosting warehouse productivity with Vecna Robotics

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Episode 611: Instawork is tackling warehouse talent shifts with flexibility and data

Mon, 28 Jul 2025 18:01:24 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin chats with Alex Vinden, General Manager of Light Industrial at Instawork. Instawork is a flexible staffing platform redefining how warehouses meet labor demands. Alex dives into Instawork’s tech-powered approach to temporary staffing, its role in collecting real-time labor data, and key insights from their latest State of Warehouse Labor report. As warehouses grapple with evolving labor needs and the uncertainty of tariffs, Alex breaks down the emerging trends and why flexibility is no longer optional; it’s essential for attracting and retaining top warehouse talent. Leveraging Data to Redefine Staffing Models Instawork stands out by blending traditional staffing needs with a tech-first model. Instead of relying solely on resumes, they analyze real-time job performance to match workers with warehouse needs better. According to Vinden, this shift provides unprecedented visibility for both staffing partners and operators. “When you’re working with a traditional agency, all of the best data that they can get comes off of the worker’s resume… whereas Instawork can go deeper and use their actual on-the-job performance.” Instawork collects data at multiple points, including wage rates, attendance, job type, and performance metrics, down to the zip code level. This data helps them stay ahead of trends. For example, they can spot wage shifts before government labor reports catch up. Their layered data approach provides warehouses with a granular view of worker reliability and performance by role. The Surprising Warehouse Talent Gap: General Warehouse Roles While skilled roles like forklift operators are traditionally harder to fill, Instawork’s recent labor report flips that narrative. “40% of [our partners] reported the biggest challenge was general labor-type warehouse roles… and 22% said pick and pack,” adds Vinden. That’s over 60% of staffing difficulty centered around what many assume to be entry-level work. As Alex explains, many companies now use these roles as top-of-funnel recruitment—training entry-level staff to grow into more technical positions. “Getting reliable people in the door consistently has been a really large challenge.” Why? General laborers now have more options, ranging from gig economy work to lower-effort roles in the hospitality industry. And when given a choice between lifting 75-pound boxes and delivering food, many opt for the less physically demanding route—especially if pay is equal. Tariff Chaos and the Case for Flexibility One of the hottest topics in warehousing right now? Tariffs. According to Alex, the industry is far from settled. “Right now we’ve seen massive decreases in CapEx and investment… People don’t know what to do.” Whether companies are shifting to 3PLs or trying to bring operations in-house, there’s a clear pattern: pause long-term decisions and stay agile. That’s where Instawork’s flexible labor model shines. “The smart approach would be to simply pause hiring, lean on temporary staffing more until you see what your business’s reality is.” This flexibility allows operators to ramp up or down based on short-term needs while maintaining productivity. For facilities investing in automation, Instawork continues to play a vital role. Manual tasks, such as loading, sorting, and final packing, often remain human-dependent and require minimal training, making them ideal for temporary workers. “Each warehouse is so unique that ramping from zero to 100… takes several weeks of getting used to it.” Key Takeaways on Warehouse Talent Wage rates have increased by 30% since 2021, but labor shortages are easing, particularly for skilled roles. The most challenging roles to fill are general warehouse labor and pick-pack jobs, not the skilled ones. Instawork’s platform collects granular data like punctuality, skill fit, and performance by task. Tariff uncertainty is halting long-term hiring, making flexible labor essential. Gen Z now makes up the largest share of the workforce, and they expect flexibility. Temporary staffing can serve as a bridge during volatility and reduce long-term cost risk. The New Warehouse Podcast Episode 611: Instawork is tackling warehouse talent shifts with flexibility and data

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Episode 610: Sonair is giving Robots a new way to see

Wed, 23 Jul 2025 12:27:55 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Knut Sandven. Sandven is the founder and CEO of Sonair, a Norway-based startup bringing new depth to robotic vision. With a background in ultrasonic sensing and two previous startups under his belt, Knut shares how Sonair is enabling warehouse robots to “see” with ultrasonic depth sensors that work in 3D. These sensors allow autonomous mobile robots (AMRs) and robotic arms to detect and navigate around various types of objects, including transparent, reflective, and oddly shaped ones. Sonair’s sensors are built on a medical-grade beamforming technique, allowing them to detect soft, hard, or glass objects with high reliability. The sensors are not only designed to enhance safety but are also being launched in safety-certified versions, helping robotics OEMs meet compliance standards more efficiently. For warehouses looking to deploy automation without reconfiguring their entire layout, Sonair’s technology could be a game changer. Reimagining Depth Perception with Ultrasound Most AMRs today rely on a combination of 2D lidars and cameras to perceive their environment. While this setup works in basic conditions, it falls short in real-world warehouses filled with glass, shadows, shiny surfaces, and unexpected obstacles. As Knut explains, “The main disadvantage with lidar is that it’s 2D… it does not see the full body of a person.” Sonair’s 3D ultrasonic depth sensor steps in to solve this problem. Based on MEMS (Micro-Electro-Mechanical Systems) technology and beamforming techniques used in medical ultrasound, Sonair delivers reliable full 3D coverage—horizontal, vertical, and everything in between. The result? Robots can detect whether someone is reaching, bending, or placing an object in their path, even if it’s a transparent or highly reflective surface. “Everything is visible in ultrasound,” Knut notes. “That’s one of the advantages.” Lowering the Barriers to Warehouse Automation For warehouse operators evaluating robotics solutions, the prospect of having to redesign layouts or halt operations can be a deal-breaker. That’s where Sonair’s tech helps simplify adoption. Knut stresses that “the goal here is really to not have to design your warehouse or the environment to the robot, but to use robots along with people in a messy environment.” By improving visibility and safety, Sonair enables robots to work seamlessly in existing spaces—no reconstruction required. In addition, Knut highlights the affordability factor: “The cost of current, safety-certified lidars is very high. We are taking that significantly down.” With Sonair’s sensors being safety-certified and plug-and-play compatible, robotics OEMs gain both cost-efficiency and quicker paths to deployment. The Future of Safety, Humanoids, and Service Robots Beyond AMRs, Sonair’s technology enables robotic arms and humanoids to operate freely without cages or barriers. Their sensors can define custom safety zones in 3D, slowing or stopping robot motion if a human enters a designated area. “You can define the safety zones in 3D. I think we are the only company having that capability,” Knut shares. As robots continue to replace monotonous and physically demanding roles, the need for reliable safety systems grows. Knut believes simplifying these systems is key to accelerating adoption: “Make safety easy. That’s where we need to go.” Looking ahead, Sonair sees big opportunities in service robotics and humanoid applications. Whether it’s delivering food in a restaurant or automating logistics workflows, Knut’s vision is clear: enable safer, smarter interactions between humans and machines, without barriers. Key Takeaways from Sonair Sonair’s ultrasonic 3D depth sensor offers full-field visibility, even detecting glass and shiny objects that cameras and lidars often miss. Built using MEMS and medical-grade beamforming, these sensors enable robots to navigate complex environments and operate safely in the presence of people. Sonair’s technology lowers the cost of safety-certified sensors while simplifying integration for robotics OEMs. Safety zones can be configured in 3D for robotic arms and machinery, eliminating the need for physical barriers or cages. By making safety easy and affordable, Sonair helps reduce barriers to automation adoption, especially in older, hard-to-retrofit warehouses. The New Warehouse Podcast Episode 610: Sonair is giving robots a new way to see

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Episode 609: Scaling Logistics with Charles Ickes of Bergen Logistics

Mon, 21 Jul 2025 13:10:56 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Charles Ickes, CEO of Bergen Logistics and CloudX Systems. With a background that began in high-end dry cleaning and led to leadership roles in fashion logistics, Charles shares how his journey shaped Bergen’s approach to global 3PL services and warehouse technology. Now operating under the Elanders Group umbrella, Bergen Logistics has grown from a regional fashion-focused provider to a worldwide network of 19 fulfillment centers—all powered by a single WMS: CloudX. Charles walks us through the benefits of owning their tech stack, how they’re helping brands navigate supply chain disruption, and why bonded warehousing and FTZs are becoming critical for fashion brands facing skyrocketing tariffs. From Couture Cleaner to Global 3PL Leader Charles Ickes didn’t enter logistics through the usual channels. His first significant step into the fashion world came as a professional dry cleaner in Manhattan, eventually leading him to a founding team role at Rent the Runway. There, he helped build what became “the largest dry cleaner in the world—we could process 6,000 dresses an hour” during peak times like prom season. Eventually, Charles was recruited to lead Bergen Logistics, a fashion-focused 3PL that has rapidly expanded its footprint. What started as five locations in the U.S. and one in Canada has now grown into 19 globally integrated facilities. This growth, he notes, is part of a strategic vision: “We now have 19 facilities that run [our] WMS… the same contracts, the same integrations, the same pricing, the same processes, the same marketing.” The key to this rapid and consistent global expansion? Bergen’s proprietary WMS platform, CloudX. CloudX: A Strategic Shift from Fragmented to Unified Many 3PLs operate with fractured systems that vary from site to site. Bergen, on the other hand, doubled down on its in-house WMS. Initially, a necessity after acquiring a fading system, CloudX evolved into a powerful differentiator. Charles explains that relying on third-party systems created operational friction: “You go to a third-party WMS and ask for software, and they’re like, ‘Well, you pay for it, then you get on the roadmap, and it takes a while.’” That lack of agility didn’t work for Bergen’s fast-paced operations. By owning the platform, Bergen could adapt quickly to customer needs and replicate its success globally for scaling logistics. “We found there was a huge competitive advantage of having your own technology. You can pivot from strategy to strategy without having the pain of hauling out all your WMS, all your systems, all your data, all your integrations,” he says. With CloudX, brands can insource or outsource fulfillment without having to start from scratch. Now supported by a 52-person team, including 26 developers and global helpdesk coverage, Charles shares how CloudX offers external brands the same flexibility. “We sell our CloudX WMS as a standalone product. So let’s say they call us and need access to the UK. Because it’s a multi-tenant platform, we can set them up right away and they’re ready to go.” Automation, Tariffs, and the Flexibility Advantage Bergen has tested various forms of warehouse automation. Charles says the ROI often falls short due to short-term contracts and varying customer needs. “It’s very hard to buy automation that’s going to solve a very specific problem for a very specific customer and think you’re going to get an ROI on it,” he explains. Instead, the company focuses on innovative process improvements, such as optimized pick paths, batching, and cart technology. “You do a discreet pick and you might get 40 units an hour. You start doing smart carts, you’re up to 80. You do batching and smart walls—you’re at 160.” These scalable, tech-enabled workflows provide the flexibility Bergen needs across its diverse customer base. Flexibility is also crucial in the face of tariff chaos. When the U.S. announced steep duties on certain imports of up to 145%, brands panicked. Charles and his team quickly organized webinars to guide clients through mitigation strategies utilizing bonded warehouses and Foreign-Trade Zones (FTZs). “We had 160 of our brands show up over five days,” he says, noting how urgent and widespread the concern was. The key distinction they taught? “In a Class 3 bonded warehouse, the tariff isn’t set until you remove the inventory. But in an FTZ, the tariff is locked in when it enters.” This flexibility enables companies to delay duties, hedge against tariff fluctuations, and enhance their cash flow. Many of Bergen’s international facilities are also FTZs, enabling global consolidation and redistribution while avoiding double duties. “If you’re in bonded, then you can export it back out without importing into the U.S., so you’ll never pay duties,” Charles adds. With fashion brands already operating on tight margins, these strategies are becoming vital to staying solvent. Key Takeaways on Scaling Logistics Bergen Logistics expanded to 19 global fulfillment centers, all of which run on the same WMS: CloudX. CloudX enables seamless transitions for scaling logistics between self-managed and 3PL operations, maintaining system continuity. Smart pick-paths and batching workflows offer better ROI than rigid automation for a flexible 3PL model. FTZs and Class 3 bonded warehouses are helping fashion brands survive extreme tariff hikes (up to 145%). The New Warehouse Podcast Episode 609: Scaling Logistics with Charles Ickes of Bergen Logistics

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Episode 608: Growth Catalyst Group on supply chain resilience

Wed, 16 Jul 2025 18:01:16 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Manish Kapoor, founder and CEO of Growth Catalyst Group (GCG), a dynamic network of supply chain-focused companies helping businesses scale with technology, process, and strategy. The conversation spans the shift from traditional distribution centers to omnichannel fulfillment, adapting to global disruptions such as tariffs and pandemics, and why the best supply chains are flexible, provide visibility, and have customer needs at the core. From FedEx and Amazon to Growth Catalyst Drawing on over 20 years of experience at companies like Amazon and FedEx, Manish shares how his team now empowers brands through GCG’s three branches: Advatix (consulting and technology), XPDEL (SMB 3PL services), and Archway (Fortune 500 in-store marketing fulfillment). Reflecting on GCG’s founding eight years ago, he shares: “Fun for us is when we help companies scale their business.” Through Advatix, XPDEL, and Archway, the team supports a diverse range of companies, from high-growth startups to Fortune 500s. GCG’s portfolio reflects this ambition. Archway supports in-store marketing for major retailers, such as Starbucks. XPDEL helps small and mid-sized brands scale eCommerce and B2B operations. And Advatix offers global consulting, custom-fit tech platforms, and a command center approach to visibility. “We are, and our goal is to be, a one-stop shop for supply chain innovation globally,” adds Manish. Redesigning Warehousing for Supply Chain Resilience Retailers no longer have the luxury of a linear supply chain, where they push products directly to stores. The rise of e-commerce shifted power to the consumer. As Manish puts it: “Now it’s shifted to fulfillment centers…because you’re fulfilling for eaches.” That shift from pallets to parcels has changed everything from warehouse layout to inventory strategy. Traditional 3PLs served B2B. Now, leaders must support both B2B and direct-to-consumer (DTC) from the same facilities. According to Manish, the most competitive players can turn a truckload into both retail casepacks and DTC orders: “If I get a truckload of a certain product SKU…I want to apply the right technology to support both.” However, that transformation requires more than just desire; it necessitates data, flexible software, and a profound understanding of your customers. Manish emphasizes starting with service level expectations: “Do your customers need same-day, next-day, or are they okay with five-day delivery?” From there, companies can design networks, select optimal sites, and develop processes based on real customer needs, rather than relying on guesswork. Resilient Supply Chains Embrace Change Manish sees supply chain resilience as the true hallmark of a strong supply chain. Rather than reacting to crises like tariffs or COVID, he urges leaders to prepare for constant disruption. “We actually say embrace the changes…these changes as a challenge just shows that you’re not prepared.” One example: the shift to multi-sourcing. With tensions between the U.S. and China, businesses are diversifying their operations. Nearshoring is a popular term, but Manish notes that even Mexico and Canada pose uncertainties. “You don’t want to put all eggs in one basket.” Still, reshoring takes time, investment, and strategic clarity. Cost pressures are also changing consumer behavior. Manish sees buyers willing to wait longer or consider used goods to avoid premium shipping costs: “That’s driving the consumer behavior to shift as well.” Inflation, capital costs, and operational efficiency are intertwined now more than ever. To keep up, companies must stay plugged in. Whether through internal teams or strong partners, it’s essential to track new technology, weigh buy, build, or partner decisions, and maintain a continuous improvement mindset. As Manish puts it: “Technology should support the most optimized operating processes—not the other way around.” Key Takeaways on Supply Chain Resilience Consumer demand has shifted supply chains from a push-based distribution model to a pull-based fulfillment model. The most competitive 3PLs today support both B2B and DTC from shared inventory, utilizing flexible technology. Tariffs, inflation, and global tensions have made resilience and adaptability top priorities. Businesses must define customer service levels before designing their network or investing in tech. Continuous improvement, flexible architecture, and process-first tech adoption are essential for staying competitive. AI is already improving command centers, call centers, and even signage compliance in stores. The New Warehouse Podcast Episode 608: Growth Catalyst Group on supply chain resilience

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Episode 607: Drop trailers unlock new warehouse efficiencies

Mon, 14 Jul 2025 13:20:55 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Andrew Wallen, VP of Distribution and Fulfillment at ITF Group, to unpack the growing role of drop trailer solutions in warehouse operations. The ITF Group positions itself as a one-stop shop for logistics services, encompassing transportation, warehousing, and global forwarding. Andrew walks us through how drop trailer strategies are helping companies reduce dock congestion, improve labor efficiency, and better navigate unpredictability in today’s supply chain. With thousands of trailers already in circulation and plans to add another 1,000 this year, ITF Group is doubling down on its commitment to innovative and flexible yard management. Why Drop Trailers Are Gaining Ground For warehouses facing space constraints, labor shortages, or unpredictable delivery schedules, drop trailers provide immediate relief. By staging trailers in advance, companies can unload or load on their timeline, without being dependent on live pickups or deliveries. Andrew explains: “We’re able to take those shipments, put them on trailers, and hopefully free up dock space. That enhances your ability to process outbound or inbound orders and frees up labor.” This model enables warehouse staff to remain productive even when trucks experience delays due to traffic, breakdowns, or hours-of-service limitations. Moreover, it reduces dock bottlenecks, a common issue during peak seasons or inventory surges. ITF’s approach helps transform trailers into temporary extensions of the warehouse itself, especially valuable in locations with unused dock doors or spacious yards. “You can use our trailers as your extension of your warehouse for dock space,” Andrew adds, underscoring the strategic advantage. How to Implement a Drop Trailer Program Adopting a drop trailer solution isn’t as simple as ordering a few extra trailers. It requires thoughtful planning, coordination, and integration with warehouse systems. Andrew recommends starting with a space audit: “Where can we drop these trailers? Do you have the spacing capacity, and how many trailers can you take on your site?” Operations must also decide whether trailers will be staged in a yard or docked directly at the doors. Some sites may benefit from using yard jockeys to reposition trailers as needed, while others may want to preload at the dock. Communication is essential, especially when syncing pickups and drop-offs with warehouse schedules. Equally important is technology integration. ITF’s drop trailer program emphasizes collaboration with customers’ yard management and dock scheduling systems to track trailer locations and status in real-time. “The most visibility will always come if the shipper or receiver has their own technology platform that we can log into,” Andrew notes. Cross-Border Flexibility and Real-Time Trailer Visibility Drop trailers also deliver unique advantages for cross-border and time-sensitive shipments. With uncertainty around tariffs and customs documentation, trailers can be pre-loaded gradually and staged for pickup when ready. “What we see with cross-border shipments is that we get to a site, and they don’t have everything ready yet. We’re able to prep that shipment ahead of time,” says Andrew. ITF has an entire department dedicated to trailer pool management. With GPS tracking and load sensors, their team can see how many trailers are at a site, whether they’re loaded or empty, and whether they need to dispatch more. “Right now, I can tell you we have close to 100 new trailers getting ready to hit the road,” Andrew shares. That visibility ensures customers always have the trailer capacity they need, without cluttering yards with excess trailers. Key Takeaways on Drop Trailers Warehouses can schedule loading and unloading on their own terms using drop trailers. Drop trailers reduce dock and yard congestion, improving both labor efficiency and safety. Drop trailers minimize the impact of common delays, such as traffic, weather, and driver shortages. Simplify cross-border shipments by staging in advance with completed customs documentation. Real-time trailer tracking ensures better visibility and operational control through ITF’s TMS. The New Warehouse Podcast Episode 607: Drop trailers unlock new warehouse efficiencies

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Episode 606: Automating yard operations with Outrider

Wed, 09 Jul 2025 15:21:29 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Andrew Smith, Founder and CEO of Outrider, a pioneer in autonomous yard operations. It’s been five years since Andrew first joined the show, and a lot has changed, both in the industry and at Outrider. The conversation explores how the company has evolved since emerging from stealth mode, how it integrates AI and deep learning into its solution, and why the yard may be one of the most dangerous, overlooked segments in the supply chain. From enhancing safety and sustainability to streamlining operations, Andrew shares how Outrider is automating the yard by creating autonomous electric trucks that maneuver trailers with centimeter-level precision. Closing the Gap Between Transportation and the Warehouse Yard operations have long been overshadowed by automation innovation, but Outrider is changing that. Their focus is on the vital yet hazardous space between over-the-road trucks and the warehouse dock, where containers are shuffled, staged, and prepped for loading and unloading. According to Andrew, “Outrider is the pioneer and leader in autonomous yard operations.” He explains how the company’s electric autonomous trucks receive trailer movement instructions via software and then locate, hitch, maneuver, and position each trailer using onboard sensors and robotic arms. “And the efficiency and safety and sustainability that we bring to the yard have benefits not just to the companies that operate these yards, but we also get the right trailer to the right loading dock at the right time, driving efficiency inside the warehouse.” This isn’t small-scale experimentation. Outrider supports yards with anything from hundreds to thousands of trailer moves per day. Their AI-driven systems eliminate the need for human drivers to perform tight maneuvers in harsh conditions, such as snow, rain, and low visibility. This reduces the risk of accidents, particularly during trailer hookups, which are prone to slip-and-fall injuries. AI in the Physical World: Why Data Makes the Difference Outrider’s evolution since 2020 has been dramatic. With more than $200 million in investment and partnerships with top tech providers, such as NVIDIA, the company has scaled its technology beyond the early proof-of-concept stage. Andrew shares a striking moment from a recent site visit: “It maneuvered in a way that a human would never even think about doing… and placed the trailer with centimeter accuracy.” This ability stems from years of AI training data and reinforcement learning, enabling autonomous vehicles to navigate even unpredictable obstructions, such as a poorly parked pickup truck or a misplaced trailer. The trucks aren’t just smart—they’re safe. “We’ve built up a set of over a dozen proprietary safety mechanisms that lay on top of the AI-driven system.” These safeguards ensure that the vehicles can operate reliably even in mixed environments with people, snowbanks, or unexpected obstacles, such as a plastic bag covering a trailer sensor. Automating Yard Operations Without Leaving People Behind Outrider’s autonomous yard trucks are built on electric platforms by design. “If there was ever an application for electric vehicles, this is it.” These short-range, high-usage vehicles are ideally suited for electrification, enabling opportunistic charging and reducing maintenance costs. Electrification also makes it easier to manage battery size, thanks to the detailed operational data generated by the autonomous system. Human workers remain essential to the operation. Outrider’s solution is built with collaboration in mind. Each truck still features a cab, allowing a worker to take over if needed. “We are creating this ultimate tool and addressing this pain point of constant turnover.” In fact, many customers are deploying automation at the same rate as natural attrition, allowing people to shift to safer, more meaningful roles while still supporting operations. Outrider is already working with companies that operate 20% of all yard trucks in North America, and Andrew is confident that their software is well-positioned to become the new industry standard. “The world’s going electric because it is the superior platform.” Key Takeaways on Automating Yard Operations Outrider automates trailer movement in distribution yards using electric autonomous trucks with centimeter-level precision. AI and real-time trailer tracking eliminate time-consuming searches for misplaced trailers, speeding up yard operations. A built-in robotic arm safely connects and disconnects trailers, reducing the risk of worker injury from hazardous manual tasks. Automating yard operations phases in automation at the pace of workforce attrition, helping companies reduce turnover without layoffs. Outrider’s platform is already being adopted by companies that operate 20% of all yard trucks in North America. Episode 606: Automating yard operations with Outrider

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Episode 605: Trailer loading with modular simplicity from Slip Robotics

Mon, 07 Jul 2025 13:18:58 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Jordan Sanders, Chief Commercial Officer at Slip Robotics. Slip has made waves in the logistics world with its ability to load or unload a 53-foot trailer in just five minutes using its autonomous SlipBots. Now, with the launch of SlipBot Plus, they’re expanding the platform’s capabilities even further, enabling highly flexible trailer configurations, safer operations, and smoother workflows. Jordan breaks down how customer feedback drove the development of SlipBot Plus attachments, why modularity matters in a chaotic dock environment, and how Slip’s U.S.-based manufacturing is positioning them to support the domestic reshoring movement. Why “Simple” Trailer Loading is the Highest Compliment Slip’s flagship solution is an autonomous, mobile staging lane that replaces manual loading with elegant simplicity. Three SlipBots act as large, motorized floors that move in and out of trailers with the push of a button. Jordan explains, “We take it as the greatest compliment when someone looks at what we do… and they say it’s simple.” What looks effortless on the surface is powered by cutting-edge robotics beneath, but simplicity drives real-world value: safety, speed, and flexibility at the dock. Because every item in a warehouse or plant enters and exits through the dock, minimizing congestion and labor strain in that space is critical. Slip enables trailers to be loaded or unloaded in five minutes, reducing dwell times and allowing drivers to return to the road more quickly, thereby eliminating detention fees and unnecessary idling. As Jordan explains, it’s just that simple. ”We always tell folks it’s the, think of it like the floor, but it moves. If you can place it on the floor, then you can place it on a SlipBot, then it can get loaded into the truck, in five minutes.” Modular Innovation: The Power of SlipBot Plus SlipBot Plus is a suite of modular attachments designed to support a wider variety of freight types. The idea came directly from customers who needed to improve cubic utilization and handle difficult freight. Jordan shares, “SlipBot Plus is modular attachments that go onto the base SlipBot platform to enable even more freight to be shipped.” These attachments include: SlipBot Plus Rack – Configurable racking for non-stackable or mixed items using standard trailer load bars. SlipBot Plus XL – Ideal for oversized items, such as 30-foot beams or heavy equipment. SlipBot Plus Edge – Designed for more ergonomic loading of floor-loaded boxes. SlipBot Plus Bin – Enables high-density packing of parcels for middle-mile and e-commerce use cases. These modular designs enable users to select configurations that match their freight profile while still utilizing the same core bot platform. As Jordan notes, “We’re all about simplicity and blending into brownfield, existing processes.” Robotics with a Human Touch Amid growing discussions on automation and labor displacement, Slip’s approach is refreshingly people-first. Their bots operate with human oversight, always requiring a person to initiate actions. Jordan makes it clear: “Our bots only move with human oversight and human command.” Slip upskills warehouse workers instead of replacing them. One memorable story involved a woman in her 60s who was thrilled to switch from physical labor to controlling the SlipBot with a game controller. “She asked her coworker to get a video of her… so she could send it to her grandson and brag that she’s a techie now,” Jordan recalls. This shift opens up dock work to a broader labor pool—older workers, individuals with limited mobility, or those without forklift certification—while reducing physical strain and injury risks. Key Takeaways on Trailer Loading 5-Minute Trailer Turnaround – Load or unload any type of trailer in just five minutes with three SlipBots. Modular SlipBot Plus Attachments – Increase trailer utilization and handle various freight types (e.g., racks, oversized goods, floor-loaded boxes). Built in the USA – Domestic manufacturing in Atlanta ensures minimal disruption from tariffs or geopolitical shifts. Human-Centered Design – Operators stay in control; bots are tools, not replacements. Hands-On Demos – Slip offers free on-site demos, allowing customers to see real ROI with their freight on their docks. Episode 605: Trailer loading with modular simplicity from Slip Robotics https://youtu.be/MEpodIxRFPE

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Episode 604: A SIMPL solution for automating warehouses

Wed, 02 Jul 2025 15:49:47 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Nicholas Gordon, Co-founder and COO of SIMPL Automation, a company redefining ASRS (Automated Storage and Retrieval Systems) deployment. Instead of tearing out infrastructure to make way for automation, SIMPL delivers an adaptive solution that installs directly onto existing racking, cutting down on cost, disruption, and environmental waste. With 15 years of integration experience under his belt, Nicholas brings a holistic view of the market and shares how SIMPL’s solution emerged from observing one consistent pain point: warehouse automation upgrades are too invasive, and too much steel ends up in the dumpster. The ASRS Market Is Evolving—Not Revolting Automation vendors are flooding the market, but Nicholas believes what we’re seeing isn’t a revolution—it’s refinement. “Right now I feel as if we’re in kind of this evolutionary state where small changes are being made… making slightly better offerings on a day-to-day basis,” he explains. This movement isn’t necessarily a bad thing. For warehouse leaders whose careers can rise or fall based on a $10–50 million automation investment, incremental improvements offer a safer path forward. But the sheer volume of options at shows like ProMat 2025, with sometimes 40 or 50 ASRS vendors, can create more confusion than clarity. According to Nicholas, “Nobody’s done a great job of addressing the long tail of brownfield facilities.” That’s where SIMPL enters the conversation, carving out space by going after the majority of warehouses that aren’t built from scratch. “If you look across North America right now… the large majority of facilities are 15, 20, 30 years old.” Instead of pushing those operations toward disruptive overhauls, SIMPL makes automating warehouses accessible by working with what already exists. Automating Warehouses with Existing Infrastructure SIMPL’s core technology installs on existing racking—regardless of whether it’s structural, roll form, pallet, or case. “We’re able to go on what you have… and our intent is to try and bring in that density and labor play… on that existing racking,” Nicholas explains. This approach not only lowers upfront investment but also avoids the soft costs overlooked in greenfield projects. “Most customers are pretty good at handling the direct costs… where I think some folks struggle is the more soft costs associated with jobs that are highly disruptive,” he notes. Those disruptions could include rerouting fulfillment to another node, flexing labor across sites, or leasing extra space. All of which have operational consequences. For some customers, SIMPL repositions racking to increase density, but it never requires a complete teardown. “We’re not going to pay for the cost of new rack, we’re just going to pay for the installation cost,” Nicholas adds. Whether a customer chooses to relocate racks or leave them untouched, SIMPL’s goal is to eliminate the high-friction decisions that typically accompany retrofits. “We’re attaching ourselves right to the face of the rack. We’re not making any modifications to it.” Simpler Bots, Smarter Operations A standout aspect of SIMPL’s adaptive system is its use of two specialized robots: one for vertical movement along the rack and one for ground transport. Nicholas is clear about the rationale: “I like my robots to essentially be specialists.” He argues that generalist robots often lead to higher costs and complexity. “That drives reliability, availability… drives down spare parts, costs, drives down preventive maintenance costs,” he explains. Their system minimizes moving parts by simplifying robot responsibilities, making long-term ownership less expensive and easier to manage. The current setup handles totes and some limited case sizes, but Nicholas hinted at what’s next: “We’ve got some stuff on the horizon… that will allow us to take on a much deeper variation in case sizes.” While he kept specifics under wraps, it’s clear SIMPL is preparing to move beyond containerized storage and into more flexible case-handling applications. And in terms of industry buzz, he’s still cautious about humanoids. “I think we’re pretty far away from a dark warehouse… It’s pretty expensive to be an early adopter of a revolutionary technology.” For now, SIMPL’s focus remains squarely on practical, immediate impact, not hype. Key Takeaways on Automating Warehouses SIMPL installs directly onto existing racking, whether structural, roll form, pallet, or case, and requires no infrastructure teardown. Leverages two specialized robots for greater simplicity, lower costs, and higher system availability Minimizes soft costs and supply chain disruptions that often go uncalculated in retrofit projects Works across greenfield and brownfield sites, enabling scalable, network-wide deployment Designed for warehouse operators prioritizing density and labor efficiency without upending operations The New Warehouse Podcast Episode 604: A SIMPL Solution for Automating Warehouses

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Episode 603: MHI’s Conveyor and Sortation Solutions Group on smarter vertical integration

Mon, 30 Jun 2025 14:24:26 +0000

Kevin chats with Wesley Parkin of Qimarox and Steve Castle of Autoquip in this episode of The New Warehouse Podcast, recorded live from ProMat 2025. Representing MHI’s Conveyor and Sortation Solutions (CSS) Industry Group, Wesley and Steve unpack key challenges and emerging solutions in material handling, especially when it comes to moving Autonomous Mobile Robots (AMRs) between facility levels. The conversation dives deep into the CSS Group’s collaborative efforts, the growing need for smarter vertical movement, and how manufacturers and integrators are adapting traditional VRCs (Vertical Reciprocating Conveyors) to meet the precision demands of modern automation. Collaboration in the Conveyor and Sortation Solutions Group The CSS Industry Group under MHI isn’t just a gathering of companies—it’s a dynamic ecosystem of manufacturers, integrators, and solution providers committed to advancing the industry through shared knowledge and innovation. As Steve explains, “There are a number of manufacturers and system integrators… whenever we come together in an industry format, we can network, we can also kind of refer to one another.” This collaboration shines in initiatives like the CSS Group’s referral sharing program. Visitors to booths can scan a QR code and submit their needs to MHI, which then shares the inquiry with group members best equipped to help. Even among potential competitors, the group fosters cooperation. “None of us have identical product lines… so if we can cross-pollinate and just help be a resource to the customer, it adds value.” Vertical Movement: The Next Frontier for AMRs As AMRs become more prevalent, the conversation about how they navigate between levels in a facility is intensifying. Wesley notes this trend is evident on the show floor: “We see more and more need for AGVs going up and down between levels… we try to advise them, show them the benefits, and help them to automate their systems.” Traditionally, VRCs were designed for manual or forklift-assisted loading. But that’s changing. Steve describes how Autoquip adapted their lifts to accommodate the sensitivity of AMRs: “With an AMR, they’re a lot more sensitive… if it drives on the VRC and there’s a big bump, your load can shift and become unstable.” Their systems now include load-height sensors and smart controls, enabling better decisions about storage placement. This integration helps maximize density and supports dynamic interactions with WMS platforms. “Once we know the height of the load… they tell us what level to go store it at so that that feedback adds value in the density.” The ROI Behind Smarter Storage and Flexibility The shift to vertical integration isn’t just about optimizing space—it’s about unlocking flexibility and long-term ROI. Wesley emphasizes the value of going up instead of out: “The floor space they would need is huge compared to if you’re going to go vertical.” Steve breaks down how storage density gets a boost from automation that accounts for real-world conditions: “If your pallet is now only 36 inches high, they know that that pallet can be stored on the top floor… It’s just adding value in little ways.” When comparing AMRs and conveyors, Steve shares a powerful analogy: “Conveyors are like a train… and AMRs are like a delivery van.” Each plays a unique role, but AMRs bring flexibility, space savings, and modularity that many facilities need. Wesley adds, “There are huge benefits in going with the AMR… in terms of redundancy, maintenance, and floor space.” Key Takeaways on Conveyor and Sortation Solutions CSS members actively refer leads to one another, creating a stronger ecosystem for customers. AMR-compatible VRCs use load-height sensing to maximize storage density across mezzanine levels. Floor space constraints and the push for flexibility are accelerating interest in vertical movement solutions. AMRs offer redundancy and modularity not possible with fixed conveyors, making them ideal for evolving layouts. Smart controls and early-stage simulation help customers plan automation projects with a clear ROI path. The New Warehouse Podcast Episode 603: MHI’s Conveyor and Sortation Solutions Group on Smarter Vertical Integration

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Episode 602: Final mile delivery savings and flexibility with Tusk Logistics

Thu, 26 Jun 2025 13:24:53 +0000

Kevin chats with Ben Emmrich, Founder and CEO of Tusk Logistics, in this episode of The New Warehouse Podcast. With experience at Google, Shippo, and deep roots in small parcel logistics, Ben brings a unique perspective on how Tusk simplifies access to a growing ecosystem of alternative parcel carriers. Designed to give shippers more control, better visibility, and meaningful cost savings, Tusk offers national infrastructure that connects shippers with both traditional regional and tech-forward emerging carriers. In the conversation, Ben explains why operators are overwhelmed by complexity, how tariffs and surcharges have forced the issue, and what he sees as the future of the parcel delivery landscape. Solving the Final Mile Pressure Cooker Final mile delivery often represents the lion’s share of a shipper’s cost line, and it’s also the most volatile. Emmrich points out that delivery costs can consume 20–25% of a shipper’s total expenses, yet many operators find themselves with limited options. “Shippers just get the living s*&t kicked out of ’em, man,” he says bluntly. With GRIs, fluctuating surcharges, and new DAS zones, the rules keep changing. Even more concerning, most operations teams are overwhelmed with daily fires such as labor callouts or warehouse system issues. “They don’t have the thoughtful bandwidth, the quiet time to like sit down and consider a single alternative, much less a network of them,” Ben explains. Tusk serves as the “infrastructure that unlocks access to a national network of alternative parcel carriers. We’re not just a tech layer—we’re the technical, commercial, and operational connection that lives inside a shipper’s TMS or WMS and keeps everything moving.” A Simpler Way to Access Alternative Carrier Networks Alternative carriers have always existed, but they’ve also always been tricky to navigate. “You have to know who they are, which ones are good, negotiate, integrate, and then coordinate multiple dock sweeps,” Ben explains. Tusk builds the infrastructure to make that easy. The company connects shippers—either brands or 3PLs spending at least $1M annually on parcel shipping—to regional and emerging carriers nationwide. On average, clients save 30–40% per parcel, and Tusk’s system allows for seamless plug-and-play integration across TMS/WMS platforms. “They had to default to the simplicity of one or two carriers,” Ben says. “We empower them to increase margins and gain leverage in their negotiations with FedEx, UPS, or the Postal Service.” It’s not just a tech solution, it’s a power shift. Why Tariffs and Postal Shifts Are Accelerating Change For many shippers, recent tariff hikes and postal shifts have made exploring alternatives a necessity. “The level of urgency for shippers to find more savings is just accelerating like crazy,” says Ben. Shifting network structures, pricing adjustments, and longer transit times have created uncertainty, even for those relying on long-established partners. “If they screwed me once, they can screw me again,” Ben says, suggesting that both brands and 3PLs are now seeking more operational flexibility. While alternatives still account for only about 4% of the parcel market, Ben sees long-term potential for a 30–45% share. He predicts that emerging carriers like Veho and Jitsu, as well as regional carriers like CDL, will continue to gain ground, mainly when shippers can utilize tools like Tusk to access them. “In that nuance is so much opportunity,” Ben says. “It’s like chocolate and peanut butter when you get it right.” Key Takeaways on the Final Mile 30–40% per-parcel savings unlocked through optimized regional and emerging carrier access Final mile costs average 20–25% of a shipper’s cost—Tusk helps reduce that burden. Simplified access to a fragmented network of alternative carriers via one integration Real-time visibility, proactive claims, and operational support are built into Tusk’s platform. The growing urgency of tariffs and USPS changes is prompting more shippers to explore new options. Episode 602: Final Mile Delivery Savings and Flexibility with Tusk Logistics

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Episode 601: Warehouse automation readiness with SLAM

Mon, 23 Jun 2025 15:39:21 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin chats with Kyle Smith of enVista and Ryan Boyd, Executive Material Handling Professional. Both guests represent the SLAM Industry Group from MHI, delving into the evolving role of Scan, Label, Apply, and Manifest (SLAM) processes in warehouse automation. This insightful conversation, recorded live at ProMat 2025, explores not just the technologies driving change but the deeper strategic mindset required to implement them effectively. As companies rush to automate, Kyle and Ryan caution that “you’ve got to walk before you run” and emphasize that successful automation readiness starts with strong internal processes and clear visibility. From building a roadmap to ensuring data-driven scalability, the discussion focuses on how to get your house in order before chasing cutting-edge tech. Let’s explore the highlights. Why SLAM Is the Starting Point for Warehouse Automation Readiness SLAM may sound like a buzzword, but it’s become a foundational concept for those looking to implement automation. Kyle and Ryan define SLAM in its practical form, scanning, labeling, applying, and manifesting, while underscoring the need to understand what’s happening within your four walls. “It’s kind of the first step for anybody that’s thinking about automating,” says Kyle. “You have to know how you’re going to do things in a given day before you’re doing them.” They also highlight how many facilities are being pushed into automation by top-down directives, often before they’re ready. One vivid example: a facility was still handling manufacturing calls via WhatsApp and wanted to automate. “The automation word gets people all fired up… but you can’t automate chaos,” Ryan adds. Instead, companies should adopt a phased, strategic approach—one that breaks automation into manageable, measurable steps and ensures each layer builds on a solid foundation. From Labels to Logistics: Building Trust and Integration into Automation SLAM may begin with labels, but the underlying challenge is to build a system that works across multiple functions. That means aligning scanning, weighing, rate shopping, label placement, and dimensioning into a seamless process. Kyle and Ryan both stress that automation isn’t about replacing humans; it’s about enhancing consistency and accuracy, particularly in the last 100 feet of the warehouse. One of the most essential elements in any automation solutions journey? Trust. “There’s been a lot of court cases in the last few years when it comes to automation technology… You really need to dive into who’s got stuff in the field that’s working,” says Ryan. They encourage customers to evaluate integrators who can pull together best-of-breed technologies from multiple vendors, rather than relying solely on single-source OEMs. This flexibility, they argue, enables integrators to address specific customer challenges more effectively and future-proof their operations against unforeseen changes. Planning for the Unknown: Flexibility, Scalability, and the Future of SLAM The conversation wraps with a powerful theme: planning for what you don’t yet know. As Ryan puts it, “Fix these six problems, and you’ll find another six. That’s continuous improvement.” Customers may not have a 10-year plan, but their data likely indicates they’ve been growing at a rate of 10% annually. That insight should inform the design of automation systems. Solutions should accommodate volume swings, growth, and changes in business model, especially as e-commerce, AMRs, and AI push the industry forward. “The most successful people are data-driven, process-driven,” says Kyle. “If you’re looking at KPIs and what your end effect is, you can back into any solution you want.” Looking ahead, Kyle predicts growing demand for traceability, consistency, and system-driven accuracy in the SLAM zone. With AI accelerating, it’s no longer about isolated solutions—it’s about integrated ecosystems that can scale both up and out. Key Takeaways on Automation Readiness from the SLAM Industry Group SLAM is more than scanning and labeling. SLAM is about visibility, consistency, and system integration Automating too early or without a clear roadmap leads to costly inefficiencies. Companies must optimize their current state before pursuing high-level automation. Integrators offer a multi-vendor, data-driven approach that’s often more flexible than single-source OEMs Trust, experience, and proven performance in the field are crucial when selecting automation partners. Episode 601 Warehouse automation readiness with SLAM

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Episode 600: Creating value in return processing with Maven Circular

Wed, 18 Jun 2025 18:39:59 +0000

Welcome to the 600th episode of The New Warehouse Podcast, recorded live from ProMat 2025. Kevin chats with married co-founders Nate and Jessica Schisler, the dynamic duo behind Maven Circular and its operations arm, Maven Fulfillment and Recommerce (Maven FR). The two bring decades of collective experience in reverse logistics, fulfillment, and circular commerce. Their mission? Help brands maximize value from returned goods while reducing waste and inefficiency across the supply chain. In this episode, they share how they went from consulting to running warehouses and why faster return processing is the hidden lever brands aren’t pulling. From Consulting to Circular Execution What started as a consulting gig helping brands improve resale and reverse logistics evolved into something much bigger. After hearing repeated client frustrations during RFP processes, one brand asked Nate and Jess a simple question: Why not run the operation yourselves? “One of our clients said, ‘Look, we know you guys know how to do this. Why don’t you go lease a warehouse and become our operator?’” said Nate. That car ride conversation led to the launch of Maven FR, a services business that now operates three warehouses in central Ohio. They continue to consult through Maven Circular, offering fractional COO-style support and operational design, but now also provide full-service returns processing, grading, and fulfillment. Their tech stack is plug-and-play for Shopify, Salesforce, Loop, and AfterShip, allowing brands to reroute returns to Maven in just days. The Cost of Delay in Return Processing At the heart of Maven’s approach is a belief that time is money. When returned inventory sits on the shelf for too long, it misses its full-price sales window, pushing it to clearance or liquidation. “What’s another word for time? It’s the cash cycle of your inventory,” Nate explained. Apparel returns are especially vulnerable. With many brands running 4-6-week sales cycles, delays can render items unsellable at full price. “If your brand has a 20% return rate… that means 20% of your inventory is unsellable because it’s in transit or unprocessed,” Nate emphasized. Maven is turning that around, with some customers seeing dock-to-stock in under 48 hours. Jessica added, “Most warehouses deprioritize returns from a labor planning perspective… so you have returns sitting at the dock for weeks.” Their solution: dedicated returns infrastructure, grading capabilities, and fulfillment—all optimized to minimize markdown risk. Unlocking Resale, Customer Loyalty, and Higher Margins Beyond speed, Maven Circular is also innovating how brands think about liquidation. Rather than offloading goods for pennies on the dollar to multiple brokers, they’re building social selling studios and running direct-to-consumer auctions. “Instead of getting 10 cents on the dollar, you’re getting 30, 40, sometimes 50 cents,” said Nate, explaining their “direct-to-consumer liquidation” model. They’re also licensed auctioneers in Ohio—another unexpected capability they’ve added to boost brand recovery rates. But the most surprising insight? Circular commerce isn’t just about sustainability. It’s also a growth lever. “Pretty reliably across our customer base… if you sell two units secondhand, you acquire one new full-price customer,” said Nate. That stat alone makes resale and returns optimization a strategic advantage for the brands ready to embrace it. Key Takeaways on Return Processing with Maven Enterprises Dock-to-stock in 48 hours reduces markdowns and speeds up inventory cash cycles. An integrated tech stack enables Shopify and Salesforce brands to reroute returns with minimal IT effort. Turn returns into an opportunity. A 20% return rate means up to 20% of inventory sits idle—Maven makes it profitable again. Missed seasons = missed revenue. With many brands on 4–6 week sales cycles, slow returns processing can prevent items from ever being sold at full price. Grading returns unlocks more value. Maven segments returns into resale, full-price restock, or liquidation, maximizing recovery across every tier. Social liquidation channels offer 3–5 times higher recovery rates than traditional offloading. For every two resale units sold, brands gain one new full-price customer. The New Warehouse Podcast Episode 600: Creating Value in Return Processing with Maven Circular

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Episode 599: SnapFulfil delivers a user-friendly WMS

Mon, 16 Jun 2025 17:59:06 +0000

Live from ProMat 2025, Kevin chats with Brian Kirst, Chief Commercial Officer at SnapFulfil, in this episode of The New Warehouse Podcast. Brian shares updates on SnapFulfil’s recent innovations, including a brand-new user interface and enhanced dashboards that are transforming the warehouse management experience. Known for its rapid deployment and configurability, SnapFulfil’s Warehouse Management System (WMS) offers tier-one functionality in a cloud-based platform. The conversation explores how SnapFulfil is helping companies gain better visibility, empower frontline teams, and stay competitive, especially in the evolving 3PL landscape. From training temps in 15 minutes to customizable dashboards that eliminate reliance on IT, SnapFulfil’s focus is on making tech work for people. Data-Driven Decisions at the Speed of Operations As warehouse complexity increases, so does the demand for real-time visibility. Brian highlights that companies are hungry for data, not just access, but clarity and actionability. “We did a market report recently… and some of the feedback we got from the market was around data. They need more data, they need to make decisions based upon that data.” SnapFulfil’s dashboards, launched last year, directly address that need. They’re customizable, self-service, and built into the product without extra cost. These tools help customers track key performance indicators (KPIs) such as supplier performance, task velocity, and item movement. “You can get all of that data out of the WMS if you have a robust enough dataset behind it,” Brian notes. And that’s precisely what SnapFulfil is providing: comprehensive, warehouse-specific analytics that operators can tailor to their own environment. A User-Friendly WMS Interface That Builds Confidence and Retention User experience isn’t just about aesthetics—it’s about operational impact. SnapFulfil’s new UI, officially launched at ProMat, offers increased configurability and performance. “You can take that view that you have as a user and customize it to your needs,” says Brian. Whether you’re in inbound receiving or inventory control, you can create workflows that make sense for your role. A user-friendly WMS matters even more in high-turnover environments. SnapFulfil’s design lets operators hit the floor quickly. “We used to describe the training process as 15 minutes, door to floor,” Brian explains. For long-term retention, intuitive navigation and mobile apps help reduce the learning curve, making it easier for users to access and utilize information. Frustration from outdated systems is a hidden driver of turnover. “If you start losing the front line, you’ve lost your main source,” Brian cautions. By listening to end users and simplifying complex processes, SnapFulfil empowers teams at every level. 3PLs Get Strategic with Tech Investment The 3PL landscape is more competitive than ever. Brian, a former 3PL owner himself, sees a shift toward smarter tech stacks and value-added services. “It’s hard to differentiate… customers are more sophisticated now,” he says. Brands are asking deeper questions, such as what WMS is in place, whether it can integrate with their ERP, and whether it supports rapid scaling. SnapFulfil is seeing increased demand from 3PLs reevaluating their tech. From automation readiness to AI preparedness, the stakes are rising. “I think it’s good for the industry ’cause it’s raising everybody up,” Brian adds. He predicts 3PLs will remain essential, particularly for brands navigating investment trade-offs between automation and operational flexibility. Why SnapFulfil’s User-Friendly WMS Makes a Real Difference The New Warehouse Podcast Episode 599: SnapFulfil delivers a user-friendly WMS

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Episode 598: Cutting transportation costs with Paccurate

Wed, 11 Jun 2025 15:02:03 +0000

Kevin chats with James Malley, co-founder and CEO of Paccurate, live from ProMat 2025 at the Paccurate booth. Known for its cartonization technology and growing ecosystem of integration partners, Paccurate is helping shippers solve one of the biggest hidden problems in logistics: packaging inefficiency. What started as a simple algorithm has evolved into a comprehensive packing intelligence platform that reduces dimensional weight costs, enhances sustainability, and enhances the end-consumer experience. In this episode, James unpacks their recent partnerships, transportation cost savings, and why bad packaging has become a brand risk. Partnerships that Eliminate “Phase Two-itis” For tech solutions to truly scale, they have to be easy to integrate. That’s where partnerships come in. “Partnerships are really everything,” James says, noting that integration delays have long held back adoption. “The biggest friction point with any API-driven product is obviously integration… once we started partnering with best-in-class WMS providers, then you can just say, ‘Just turn it on and measure it.’” Paccurate’s latest partnerships include Kardex, SVT Robotics, Logiwa, and Packsize. Each adds unique synergy. For Kardex, the value lies in connecting cartonization to automated storage and retrieval (AS/RS) systems. “What happens right after the goods come out of the AutoStore? We need to figure out how to pack it. If I can bring Paccurate in at the same time… now you’re lowering transportation costs without trying too hard.” By becoming part of a “balanced breakfast” of warehouse automation, Paccurate turns what was once a “phase two” afterthought into a frontline enabler of efficiency. From Pack Station to Parcel: Real Transportation Cost Savings While smarter packing improves labor and material usage, the real payoff is downstream. “Transportation cost savings are like, I don’t know, 70% of the savings of doing something like what we have,” James explains. The platform removes void fill and air from boxes, optimizing every shipment for maximum efficiency. While smaller brands have seen reductions of up to 20% in transportation costs, James notes that even a 4% drop at scale yields substantial financial returns. On average, customers save about 6% compared to older cartonization systems. And the benefits compound. “Doing advanced cartonization like this will save you pretty much the same amount of money in total as an AMR system, with none of the risk,” James says. For cost-conscious shippers, it’s an immediate ROI win that doesn’t require the complexity of full-scale automation. When a Bad Box Becomes a Brand Crisis It’s not just logistics teams paying attention—CEOs are picking up the red phone, too. “You’d be surprised how many cartonization emergencies there are,” James laughs. All it takes is one viral TikTok post showing a poorly packed box to trigger executive action. That urgency is only growing. “Gen Z is the first generation that will actually make changes to their buying behavior if they perceive a brand to be wasteful,” he says. Unlike Millennials, who might just grumble, Gen Z consumers act by not buying again. That makes smart packaging not just a cost saver, but a reputational safeguard. The convergence of sustainability, cost reduction, and consumer expectations is pushing packaging out of the shadows. What used to be “just the cost of doing business” is now a competitive differentiator. Key Takeaways The New Warehouse Podcast Episode 598: Cutting transportation costs with Paccurate

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Episode 597: Making Warehouse Automation More Accessible with iAutomate

Mon, 09 Jun 2025 14:29:36 +0000

Warehouse automation doesn’t have to be a mystery or a million-dollar risk. In this episode of The New Warehouse Podcast, Kevin chats with Christoph Buchmann, Co-founder and Managing Director of iAutomate, live from ProMat 2025. Together, they explore how iAutomate is bridging the information gap for companies looking to implement automation without the usual guesswork. Christoph shares live insights from the ProMat show floor and discusses the changing landscape of entry-level automation solutions. Whether you’re a small warehouse exploring automation for the first time or an enterprise looking to scale smartly, Christoph’s perspective offers a grounded view on what’s happening and what’s next. Entry-Level Warehouse Automation Is Having a Moment It’s not just the big players looking at automation anymore. According to Christoph, “automation has become more accessible, more available because there are a lot of new technologies and solutions that are just more entry-level.” The shift is evident on both fronts: companies are seeking scalable solutions that can start small and grow, and the iAutomate app is reflecting this trend in real-time. “We can see which technologies are how popular, what’s the frequency of usage… The trend is definitely going towards scalable entry-level automation solutions,” Christoph said. This “crawl-walk-run” approach enables companies to build momentum without incurring massive costs or committing to extensive infrastructure. Accessibility doesn’t stop with the technology itself. iAutomate gives users visibility into “size, capacity, price,” and even helps them validate whether a solution fits their needs, before they ever walk into a demo. From Guesswork to Guided Strategy One of the most significant barriers in automation has always been the answer to a simple question: What does it cost? Christoph put it bluntly: “The answer should not be ‘it depends.’” He likens the experience to configuring a car online—you should be able to get a ballpark number for your automation investment without calling an engineer. That’s the value iAutomate brings to the table. Users can explore viable technologies, narrow down their options, and arrive at ProMat ready to ask more informed questions. “They can now engage at a much more accelerated level,” Christoph explained. Instead of wandering the expo floor overwhelmed, users come prepared with knowledge and intent. This shift benefits solution providers as well. As Christoph noted, “It creates a win-win situation between those looking for automation and those providing it.” Navigating the Realities of Warehouse Automation After Go-Live Despite the excitement surrounding new technology, many companies still face harsh realities after implementation. “They bought automation for the right reasons,” Christoph said, “but we’re really struggling to get the performance out of it.” In some cases, customers feel abandoned post-installation, facing maintenance and troubleshooting challenges on their own. Others are overwhelmed by the sheer volume of options available, unsure of what will deliver actual return on investment (ROI). To help with both, iAutomate doesn’t just serve as a validation tool; it also helps foster peer-to-peer connection. “We want to connect people who’ve done automation with those who are trying to do automation,” said Christoph. Looking ahead, he believes that automation will only become increasingly critical. “If you don’t start looking at ways to automate your supply chain now… You might get caught off guard.” From real estate constraints to labor shortages in cold storage, the macroeconomic drivers are intensifying. And iAutomate is betting that innovative, scalable solutions, plus access to trustworthy information, will lead the way. Key Takeaways Listen now to EP 597: Making Warehouse Automation More Accessible with iAutomate

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Episode 596: Warehouse orchestration with AutoScheduler

Thu, 05 Jun 2025 07:00:11 +0000

In this episode of The New Warehouse Podcast, Keith Moore, CEO of AutoScheduler AI, shares valuable insights into how warehouse orchestration and artificial intelligence are transforming distribution operations. AutoScheduler focuses on harmonizing data from diverse warehouse systems, applying advanced optimization techniques, and providing analytics to enhance warehouse efficiency and productivity. Moore examines how the landscape of warehouse operations is evolving, with roles specifically designed to address growing complexities through orchestration. He also clarifies common misconceptions about AI, highlighting the practical ways it can significantly improve operational effectiveness by automating complex decision-making processes. Warehouse Orchestration: The New Normal Moore defines warehouse orchestration as the coordination of disparate data systems, such as warehouse management systems (WMS), inventory management, and yard management, into a unified view. “Continuous improvement with a technology angle is moving into orchestration,” he explains, highlighting the new specialized roles emerging in this space. Companies now recognize that having a dedicated orchestration function is vital because warehouse managers often juggle information across multiple, fragmented systems. Kevin and Moore humorously suggest these new roles could aptly be called “warehouse conductors” or “maestros,” given their pivotal role in harmonizing operations. AI’s Real Role in Orchestrating Warehouses Addressing the AI hype, Moore emphasizes the practical applications of artificial intelligence within warehouse settings. “Generative AI struggles in a warehouse because warehouses have a particular set of data,” Moore notes, clarifying that generative AI’s strengths lie outside the structured data typical of warehouses. Instead, effective AI in warehousing encompasses predictive analytics and decision optimization, which determine optimal inventory flows, labor utilization, and productivity enhancements. Moore cites specific AI applications, such as optimizing pick routes, dynamic slotting, and yard management, as prime examples where AI delivers a significant return on investment (ROI). Navigating AI Integration: The Practical Steps Integrating AI into warehouse operations isn’t as daunting as it seems, Moore asserts, outlining critical steps to ensure successful implementation. He advises operations leaders to first confirm whether a human with sufficient time and data could theoretically solve the problem before applying AI. Before launching any AI initiative, Keith says you need to ask two key questions: First, “if you gave a person all the data and unlimited time, could they solve the problem?” If not, it’s not the right fit for AI. Second, “Can you map your data directly to a specific process in your operation?” Without that connection, even the best models will fall flat. AI only works when you have both a solvable problem and a clear path from data to decision. He also shares how businesses that invested in foundational data harmonization five years ago are significantly ahead, underscoring the value of clean, structured data in achieving operational goals. Key Takeaways on Warehouse Orchestration Warehouse orchestration integrates fragmented data systems to streamline operations. Specialized orchestration roles are becoming common, reflecting the complexity of modern warehouses. Practical AI applications include optimizing pick routes, dynamic slotting, and predictive analytics. Precise data-process mapping is essential before integrating AI. Data harmonization significantly boosts the effectiveness and return on AI investments. The New Warehouse Podcast Episode 596: Warehouse orchestration with AutoScheduler

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Episode 595: Warehouse automation solutions without the sales pitch

Mon, 02 Jun 2025 12:16:37 +0000

Welcome to this episode of The New Warehouse Podcast, featuring Allison Myers and Dan Gilmore from MHI’s Solutions Community. MHI is a leading industry organization committed to advancing material handling and supply chain practices. In today’s discussion, Allison and Dan introduce the Warehouse and DC Solutions Network, which connects warehouse operators with tailored automation and solution providers. They explore how this platform addresses key industry challenges such as labor shortages and complexity in automation selection, offering warehouse managers a streamlined way to discover optimal solutions. Anonymous Matchmaking for Warehouse Automation Solutions MHI developed the Warehouse and DC Solutions Network as a matchmaking tool. As Gilmore explained, this platform “allows companies to anonymously submit their problem, opportunity, or challenge,” which is then reviewed and responded to by over 100 vetted vendors with tailored solutions. This anonymity ensures operators can explore automation solutions without fear of being inundated with unsolicited sales pitches. Myers emphasized, “It’s just solutions, no sales pitch,” allowing users to evaluate technology without external pressures. Leveraging Collective Industry Expertise The Warehouse and DC Solutions Network stands out because it harnesses the collective expertise of over 100 companies within MHI’s Solutions Community. According to Myers, the community represents a collaborative industry effort aimed at addressing labor shortages and enhancing warehouse efficiency: “We all together rise, rise together better than separate.” By pooling knowledge from diverse automation providers, the platform offers warehouse operators comprehensive insights, potentially uncovering innovative solutions they might not otherwise discover. Gilmore added, “You may get four or five back, but you like number one, number three, and number four…you’re gonna say, ‘I’d like to engage with these three companies.’” Simplifying the Search for Warehouse Automation Solutions Many warehouse operators may find traditional web searches limiting, as they primarily return sponsored results rather than genuinely helpful solutions. The Warehouse and DC Solutions Network provides an objective, solution-oriented alternative. Gilmore noted, “If you do a Google search on warehouse automation…you’re gonna get a page of sponsored ads,” highlighting the benefit of this more targeted, tailored approach. The simplified four-step submission process through MHI’s platform ensures warehouses can quickly articulate their challenges and efficiently receive valuable feedback from leading industry solution providers. Key Takeaways The Warehouse and DC Solutions Network provides an anonymous platform for connecting warehouses with automation solutions, eliminating unsolicited sales pressure. Over 100 companies contribute diverse expertise, providing robust and tailored solution options. A streamlined four-step submission process enables warehouse operators to identify relevant solutions quickly. Initial feedback can typically be expected within a few weeks, offering timely guidance without the need for extensive research or travel. The New Warehouse Podcast Episode 595: Warehouse Automation Solutions Without the Sales Pitch

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Episode 594: A skinny pallet jack, big savings, and the power of innovation

Wed, 28 May 2025 13:02:49 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Dan Betz, Executive Vice President of Operations at Andrews Distributing, a family-owned beer and spirits distributor serving 13,000 customers with over 45 million cases delivered annually. Based in Dallas-Fort Worth and Corpus Christi, Andrews is known for its commitment to continuous improvement and operational innovation. Dan shares how a costly inefficiency in their direct-store-delivery model led them to co-develop a custom solution: the Skinny Pallet and Skinny Pallet Jack. This unique approach to delivery logistics, enabled through a partnership with Big Joe and Peninsula Pallets, not only slashes waste but also enhances service for both customers and drivers. Rethinking Direct Store Delivery to Eliminate Waste For Andrews Distributing, the direct store delivery model presents a logistical maze, especially when over 50% of stops require navigating narrow 36-inch doors. “Every case, 45 million cases at Andrews, has to be checked in by hand,” Dan explained. “So you’re taking time away from a store clerk or a store manager… or we’re waiting on them while they’re taking care of the customer.” To understand where they were losing time and money, Dan’s team value stream mapped the entire delivery process, from when a truck leaves the warehouse to when it returns. They found it eye-opening: 25% of delivery time was spent in the check-in process alone, translating into $5 million in labor costs. “We look at that as waste or muda. Of that 5 million, we can cut it in half,” Dan shared. The issue? Conventional pallets and jacks simply don’t fit. Not only are standard 40×48 pallets too wide, but their forklifts and jacks are too heavy to enter retail spaces, forcing teams to break down every load manually. The Birth of the Skinny Pallet and Skinny Pallet Jack Instead of accepting the inefficiency, Dan and his team, backed by decades of frontline experience, started designing a solution themselves. “We said we need a skinny pallet to get through that door and a Skinny pallet jack light enough to get on the floor.” They faced numerous rejections from manufacturers, many of whom dismissed the idea as too ambitious. But then a meeting with a Fort Worth distributor led them to Big Joe. Within seven days, Big Joe’s president and VP of engineering sat down with Andrews and asked a powerful question: “What do you need?” “We told them exactly what we needed for our business… They said, ‘We got you.’ And they did it,” Dan recalled. “Everything they did was exactly to spec that we needed.” Together with Peninsula Pallets and Big Joe, Andrews created a narrow, stable pallet that could fit through skinny doors and pair with a custom jack outfitted with a weight scale, enabling check-ins by weight instead of manually scanning each case. Case Study – Integrated Lithium-Ion Pallet Truck for Beverage Delivery “There’s no one out there today who’s checking in product by pallet by weight… The weight scale is the gold.” Delivering Value Beyond Beer Initial results have been staggering. The system saves time and money, dramatically improving the delivery experience for both store staff and Andrews’ drivers. “We just believe that, as brand builders, we can really be our very best to serve our customer and the customer’s customer.” By reducing check-in time, Andrews estimates a savings potential of $2 to $2.5 million internally. But the implications are much broader. If scaled industry-wide, this method could eliminate $130–$150 million in waste across the U.S. beer industry’s 3 billion cases delivered annually. “This thing can go into other industries—whether it’s water or soda. We ever store deliver.” Dan also noted how innovation requires courage, not just from the companies seeking change but from vendors willing to take risks. “First of all, you’ve got to state your case and state it clearly… If they can’t see that, you push. You try again.” Thanks to Andrews’ perseverance, what began as a pain point at the back door has become a platform for innovation that could reshape store delivery across industries. Key Takeaways Andrews delivers over 45 million cases annually across 13,000 customers. Value stream mapping revealed that 25% of delivery time, worth $5M, was spent on manual check-ins. The skinny pallet jack, co-developed with Big Joe, successfully navigates 36” doorways and weighs pallets for faster check-in. Switching to check-in by weight could cut $2.5M in costs at Andrews and up to $150M industry-wide. The concept is scalable to other industries like water, soda, and other store-delivered goods. The New Warehouse Podcast Episode 594: A skinny pallet jack, big savings, and the power of innovation

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Episode 593: Dock management solutions from Conduit that put you in control

Tue, 27 May 2025 12:53:19 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Conrad Lilleness, Co-founder and CEO of Conduit, live from Manifest 2025. Conduit is a modular dock and yard management system used by companies like Volvo, Saks Fifth Avenue, and Body Armor to streamline truck scheduling, check-in, and onsite communication. What started as a scheduling platform evolved into a robust dock management solution that digitizes operations across the yard. Conrad shares how Conduit helps companies boost throughput, improve safety, and use real-time data to uncover hidden inefficiencies, turning the dock into a strategic asset. From Scheduling to Full-Fledged Dock Management Conduit began with a simple idea: build the easiest-to-configure scheduling module on the market. That alone proved valuable, but customers quickly asked for more. “We started with several packaging companies and manufacturers, but they very quickly helped us overcome that next product hurdle, which was the check-in technology,” Conrad shared. The next leap forward came with Body Armor, where Conduit became a standard operating tool across 13 facilities. “In the Body Armor Network, 95% or more of drivers are checking in entirely independently without leaving their trucks,” he explained. By eliminating manual check-in and yard foot traffic, Body Armor improved efficiency and safety, an especially vital upgrade in high-risk areas like the yard. Transforming Customer Service and Labor Planning Conduit’s latest innovation is a centralized Control Tower empowering customer service reps and transportation analysts. Traditionally, resolving a proof of delivery request might involve 20 emails or a game of phone tag. Now, reps can search across multiple sites using PO numbers, carrier names, or other identifiers and get instant access to audit logs, delivery documents, and performance data.“A centralized customer support team can now access all of their facilities through one pane of glass,” Conrad noted. The platform also helps customers solve long-standing labor inefficiencies. For instance, a Washington-based produce distributor used Conduit to analyze when trucks arrived, what they carried, and how long unloading took. “They were able to cut their overtime by 50% and really improve employee experience with better shifts,” he said. The Dock as a Strategic Asset Looking ahead, Conrad sees the dock becoming more central to warehouse strategy. That means more than just optimizing labor. It’s about owning and using the data to make better decisions. “At Convoy, we spent a lot of time reverse engineering our customers’ scorecards,” he recalled. “But with Conduit, we’re arming these facilities and the transportation teams that these facilities support with their own first-party data.” This transparency empowers shippers to enforce service-level expectations with complex data. It also helps manage trade-offs, such as whether to incur container storage fees or absorb labor overtime. Conduit is now exploring seal verification workflows and AI-powered tools to automate document recognition, such as handwritten notes and seal conditions, areas traditionally left to manual, error-prone processes. “SEAL verification is like the wild west,” he quipped. “Some facilities don’t even look at the seal.” Key Takeaways on Dock Management Conduit enables 95%+ driver self-check-in at Body Armor sites, reducing yard congestion and improving safety. Customers use Conduit’s centralized Control Tower to access documentation and streamline customer support across multiple facilities. One distributor cut overtime by 50% after using Conduit’s data to restructure labor shifts. Shippers can now use Conduit’s data to hold carriers accountable for delays and negotiate performance-based terms. The New Warehouse Podcast Episode 593: Dock management solutions from Conduit that put you in control

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