Warehouse Management 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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Antares Vision Group plays active role in Michigan State University Study on utilizing RFID technology for DSCSA-compliant Pharma Traceability

Fri, 25 Jul 2025 10:15:04 +0000

The company provides serialization software and project guidance to the Axia Institute’s end-to-end RFID Pilot Program. Antares Vision Group played a key role in the latest phase of an ongoing study by Michigan State University’s The Axia Institute (“Axia”) that tests the feasibility of applying RFID technology to streamline pharma traceability throughout the supply chain. For the study’s second phase – the results of which have been published by Axia, part of MSU’s Office of Research and Innovation – Antares Vision Group provided mission-critical serialization software, and shared its decades of expertise and traceability leadership to help inform and optimize the study’s procedures. The most recent effort comprised Phase 2 of Axia’s End-to-End RFID Pilot program. The study’s initial phase demonstrated the technical feasibility of applying RFID to various drug formulations and pharmaceutical packaging types in a laboratory setting; Phase 2 significantly expanded the scope to test the robustness and interoperability of RFID across the pharmaceutical supply chain, in alignment with GS1 standards and the United States Food and Drug Administration’s Drug Supply Chain Security Act (DSCSA) requirements. The overall project hinges upon the development of the Axia Observer Platform, an IoT-based software solution designed to track materials across the supply chain using both RFID scans and Electronic Product Code Information Service (EPCIS) supply chain event data. The system is designed to provide real-time monitoring, anomaly detection, master data integration, and product flow integration, among other attributes. Antares Vision Group provided its traceability solution to meet the tracking and compliance reporting required under DSCSA, which are essential to protecting patient safety. As one of the global leaders in pharmaceutical serialization and supply chain security, Antares Vision Group brought the experience, systems, and operational comprehension needed to ensure the pilot reflected the realities of daily industry operations while fully aligning with regulatory requirements. For Phase 2 of the pilot program, testing was conducted using four full pallets of pharmaceutical products comprising varying formulations and packaging sizes. Crucially, experiments transpired across diverse environments – including the Axia Lab, which simulated manufacturing and pharmacy settings, and the nearby distribution center of partner company Cencora. By any measure, Phase 2 results were exceptionally encouraging. The prototype RFID system successfully tracked each of the nearly 7,000 individual products, with all inconsistencies automatically identified and corrected in real-time. This 100% success rate demonstrates the system’s value as a scalable complement to barcoding for DSCSA and other international compliance regulations. “The results of this pilot reaffirm the critical role that serialization and track-and-trace technologies play in securing the pharmaceutical supply chain,” said Herb Wong, Chief Customer Officer, Antares Vision Group. “By integrating our serialization solutions with advanced RFID and real-time monitoring platforms, we’re able to drive both compliance and operational efficiencies for our partners. This successful collaboration with Axia demonstrates a clear path toward scalable, DSCSA-compliant digitization.”

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Toshiba’s Debra Anne Kellogg wins Bronze Stevie® Award

Fri, 25 Jul 2025 10:00:37 +0000

The Stevies named Kellogg a “Culture Transformation Leader of the Year” Toshiba America Business Solutions’ Debra Anne Kellogg wins the Bronze Stevie® Award for “Culture Transformation Leader of the Year.” “We congratulate all of the winners in the 10th edition of the Stevie Awards for Great Employers for their outstanding performance,” says Stevies President Maggie Miller. “Toshiba’s Debra Anne Kellogg is a sterling example of one who goes above and beyond to educate and inform her teammates while making a distinct and positive impact on her company.” The Stevie Awards for Great Employers recognize the world’s best employers and the human resources professionals, teams, achievements, and HR-related products and suppliers who help to create and drive great places to work. More than 100 professionals from around the world participated in the judging process to determine this year’s honorees. Winners in the Employer of the Year categories were determined by a combination of ratings from Stevie Awards judges and more than 130,000 public votes. Toshiba’s Difference Maker Kellogg led a cross-country Toshiba task force to create a new nationwide culture training program for nearly 1,950 company employees. Implementing input from company leaders, she completely revised the organization’s training program with all new content emphasizing Toshiba’s values, which include empowering others, seeking innovation and delivering the exceptional. The resulting multi-tiered rewards platform, recognizing employees who go above and beyond, while also demonstrating the company’s values, is the hallmark of Kellogg’s aptly named ‘Be the Difference’ program. Stevie judges believe Toshiba’s learning and development leader is a difference maker at her company. One judge comments, “Debra Kellogg reads like the steady, quiet force in the background, the kind of leader who isn’t chasing the spotlight but whose fingerprints are on everything that actually moves the company forward. Thirty-three years at Toshiba isn’t just tenure; it’s a lifetime of learning how to stitch people and values into the fabric of an organization. What strikes me most here is the humility and the hands-on craft behind ‘Be the Difference,’ no outside consultants, no flashy gimmicks, just deep, earnest work to create something that feels real and owned by the company itself. This is culture-building at its purest, thoughtful, slow, and genuinely people-centered.” “Upon working for more than a year to create our ‘Be the Difference’ national culture training program, Debra brings our mission, vision,n and values to life here for everyone at our company,” states Toshiba America Business Solutions Vice President of Human Resources Kim Jones. “Thanks to her inspiration, passion, and hard work, we now have a practical way for our nationwide employees to connect with what matters most at Toshiba, and it’s having a positive impact on how we work together each day.”

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AutoScheduler receives investment from Ben Gordon, founder of Cambridge Capital LLC

Wed, 23 Jul 2025 13:17:55 +0000

Investment to further growth of Agentic AI-Based Warehouse Orchestration solutions AutoScheduler.AI has announced receiving a strategic investment from Benjamin Gordon, a leading investor in logistics and supply chain technology companies. This investment marks a significant milestone in AutoScheduler’s continued growth and commitment to transforming warehouse orchestration through Agentic AI. “Ben Gordon brings unmatched expertise in logistics technology and a proven track record of scaling high-growth supply chain innovators,” says Keith Moore, CEO of AutoScheduler AI. “Ben understands that we’re entering a new era in warehousing, where Agentic AI enables proactive, intelligent decision-making across operations, driving speed, agility, and performance. This strategic partnership will help us accelerate our roadmap, enhance customer outcomes, and bring Agentic AI warehouse orchestration to even more enterprises.” “In a world where disruptions are the norm, companies need intelligent, responsive systems that can orchestrate warehouse operations in real time and AutoScheduler delivers exactly that and more,” says Benjamin Gordon. “We are impressed with the team, technology, and leadership at the company and look forward to supporting their continued growth.” Benjamin Gordon is Managing Partner of Cambridge Capital, an investor in niche supply chain leaders. He is also Managing Partner of BGSA Holdings LLC (BGSA), an investment banking firm focused on the supply chain industry. Prior to founding BGSA, Ben founded 3PLex and led strategy projects in transportation and technology at Mercer Management Consulting. Ben received a Master’s in Business Administration from Harvard Business School and a Bachelor of Arts degree from Yale College. AutoScheduler continues to partner with global brands seeking to modernize warehouse operations and boost efficiencies and productivity within the warehouse environment. The investment will support AutoScheduler’s continued expansion, including enhancements to its product suite, growth of its leadership and engineering teams, and increased go-to-market efforts. Previous investments & follow on investments were also made by core AutoScheduler partners Noro-Moseley Partners and Blue Impact LLC.

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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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From fulfillment to foresight: How warehouse data is driving the next wave of sales innovation

Sun, 20 Jul 2025 05:00:56 +0000

For years, warehouse operations have been tasked with keeping up, responding to demand, scaling with the season, and getting orders out the door. But that dynamic is shifting. With the rise of AI, automation, and real-time data, warehouses are no longer just fulfilling sales trends — they’re helping to shape them. In today’s data-rich supply chains, distribution centers are emerging as sources of commercial intelligence. From pick velocity and slotting efficiency to inventory aging and inbound constraints, warehouse data is shedding new light on what’s actually possible, profitable, and promotable. It’s no longer just about whether you can fulfill a promotion — it’s about whether the warehouse can help decide which promotions make sense in the first place. From execution engine to sales co-pilot Modern WMS platforms are no longer passive record-keepers. They’re active intelligence hubs, capturing real-time signals about how goods move, where delays occur, and what can be optimized. These insights are becoming increasingly valuable to sales and marketing teams seeking an edge in a competitive environment. Consider picking velocity data. When the warehouse identifies SKUs that move quickly through the system — in and out with minimal touchpoints and labor — those become ideal candidates for sales pushes or bundled deals. Aging inventory in accessible locations might present an opportunity for a flash promotion to clear space ahead of a seasonal shift. Even upstream data, like bottlenecks in inbound receiving due to shipping patterns, can inform timing decisions for major sales events. In short, the warehouse is becoming a partner in the planning process, not just the final step in execution. The rise of manufactured demand events Sales trends today are increasingly orchestrated. Retail has long embraced this model — think Prime Day, Old Navy’s $1 flip-flops, doorbusters, and BOGO sales — but it’s extending well beyond consumer environments. Distributors and B2B sellers are finding value in engineered velocity events: intentional sales campaigns designed to boost volume, clear stock, or introduce new product lines. These events rely on tight coordination between commercial strategy and supply chain execution. And they’re only possible when the warehouse can provide both the operational capacity and the data-backed confidence to support them. For example, imagine a distributor sitting on excess inventory of a product with high pick efficiency and broad appeal. Rather than wait for organic sales to recover, the company can coordinate a campaign, timed to when the warehouse has capacity, informed by margin analysis, and executed with the precision of automation. The result is not just a successful promotion, but one that’s operationally viable, strategically timed, and executed with the consumer experience in mind! The cost of siloed decision-making Too often, promotional decisions are made in isolation. Sales and marketing teams launch campaigns based on customer insights or competitive pressures, while the warehouse is left scrambling to fulfill a spike it didn’t see coming. The cost of this disconnect can be high, in stockouts, missed SLAs, overtime, and degraded customer experience. The antidote is tighter integration. With real-time warehouse data informing commercial decisions, companies can engineer demand without compromising execution. AI plays a critical role here — not just in automating tasks, but in connecting data streams across departments and surfacing patterns that human planners might miss. The best-run operations are using this visibility to run smarter, not just faster. They’re deciding when to sell more, what to promote, and how to align incentives across the business — all with the warehouse in the room. Sales enablement starts in the warehouse It’s time to stop thinking of the warehouse as a cost center that follows the lead of sales and start recognizing its role as a revenue enabler. The intelligence generated on the warehouse floor can — and should — be a key input to commercial planning. With AI-enhanced WMS platforms, real-time adaptive automation, and cross-functional collaboration, distribution operations are helping businesses not only respond to demand but also shape it. The question isn’t just “can we fulfill this promotion?” It’s “should we run it — and when — based on what the warehouse knows?” That shift in mindset is subtle but powerful. And as more companies embrace it, we’ll see smarter sales trends — not just faster fulfillment. About the Author Vee Srithayakumar is a product leader in warehouse management at Tecsys, driving innovation through AI-driven and advanced warehouse execution system initiatives. His contributions to the supply chain industry earned him recognition as a 2024 Supply & Demand Chain Executive “Pros to Know.”

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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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Swisslog appoints new Americas region president and CEO

Wed, 09 Jul 2025 15:33:44 +0000

Swisslog has announced Mike Barker as the company’s new president and CEO of Swisslog Logistics, Inc. Mike will drive the company’s growth in the Americas and key industries, bring renewed focus to evolving and enhancing Swisslog’s SynQ software, enhance the company’s integrated solutions, and develop strategies for further AI integration into Swisslog’s portfolio of best-in-class robotics and software solutions. “Outgoing president and CEO Sean Wallingford significantly contributed to the company’s success in the Americas region, accomplishing record-setting growth and establishing new customer partnerships. As we move into this next chapter, we do so with a strong foundation in the Americas region that he helped build,” said Jens Schmale, CEO of Swisslog. “I am confident that Mike is the right person to further accelerate the company’s success in the Americas region. His leadership, insight and commitment to the customer is exactly what is needed to maintain the company’s forward progress. I’m excited to see where his leadership takes Swisslog.” Mike brings over 34 years of experience in warehouse automation, logistics and software, coming back to Swisslog after serving as Vice President of Consumer Goods at Swisslog in 2021. He brings a wealth of expertise and knowledge to his new role with Swisslog, including defining corporate strategies to support the evolution and enhancement of software offerings. He also has valuable experience working closely with sales, product management and engineering to align with corporate goals, as well as leading professional service teams in deploying large scale software solutions. “Swisslog provides innovative value to customers through the power of integration, the physical aspect of uniting multiple solutions on a single platform and the software aspect of providing a single point of control for managing the various subsystems that go into the solution. Our ability to deliver smart automation and collaborate closely with customers is unmatched,” said Mike, “I’m excited to rejoin the company and eager to build on these strengths to increase our market share and bring further innovation to our automation solutions and software to help our customers continue to meet the needs of their evolving supply chains.” Given Mike’s software experience, he sees a real opportunity to enhance Swisslog’s SynQ software to provide further benefits to customers. SynQ not only optimizes the flow of the equipment to increase efficiency and accuracy of the operation, it also orchestrates the operation of multiple systems. SynQ is equipping warehouse automation and IT systems with synchronized intelligence of people, processes and machines to boost the efficiency and productivity of warehouse processes and adapt to changing market requirements.

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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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Hai Robotics and Conveyco join a strategic partnership

Wed, 25 Jun 2025 13:37:51 +0000

Conveyco and Hai Robotics have announced a partnership to help businesses optimize warehouse storage, streamline fulfillment, and maximize operational efficiency through cutting-edge automation solutions. The collaboration brings Hai Robotics’ HaiPick ASRS solutions into Conveyco’s portfolio, delivering transformative benefits to end users. These ultra-dense, modular goods-to-person systems increase operational efficiency by up to 400%, daily throughput up to 300%, and order picking accuracy to over 99% — all while reducing storage footprints by as much as 75%. “At Conveyco, we are committed to delivering innovation that drives real, measurable improvements for our customers,” said Ray Cocozza, CEO of Conveyco. “Partnering with Hai Robotics allows us to bring state-of-the-art technology to the table, helping businesses modernize their operations in ways that are both scalable and sustainable. This collaboration strengthens our ability to provide custom, reliable solutions that not only meet current needs but are adaptable to future growth.” “We’re excited to partner with Conveyco, whose deep industry expertise and consultative approach make them an ideal match for Hai Robotics,” said Hunter Senn, Vice President of Sales at Hai Robotics USA. “This partnership expands access to our flexible goods-to-person systems and helps more businesses take the next step in their automation journey — whether they’re upgrading an existing warehouse or launching a new facility.” A key advantage of HaiPick Systems is their modular, flexible design, which integrates with traditional racking and operates with minimal or no floor modifications, making them ideal for businesses looking to boost performance without pausing operations for heavy facility renovations. The system’s modularity also enables seamless expansion and reconfiguration, giving businesses the flexibility to scale and adapt as their needs evolve. HaiPick’s ability to support diverse storage environments and container sizes — paired with high throughput rates — makes it a strong fit for industries like e-commerce, third-party logistics (3PL), manufacturing, apparel, healthcare, and more that need both agility today and scalability for tomorrow. “This relationship underscores our commitment to being a trusted journey partner for our clients,” Cocozza said. “We’re not just providing automation tools; we’re delivering strategic solutions that empower businesses to operate more efficiently, reduce costs, and stay competitive in a rapidly changing market.”

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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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Tech-savvy managers: The cornerstone of modern warehousing

Fri, 20 Jun 2025 05:00:36 +0000

Warehouses are evolving into hubs of cutting-edge technology, but without the right leadership even the best tools can fall short. The need for tech-savvy managers has never been greater as logistics operations become increasingly dependent on automation, data analytics, and advanced Warehouse Management Systems (WMS). Technology is no longer a luxury — it’s a necessity. Managers must now think beyond traditional roles, embracing software as a solution to physical problems in workflows. Those who fail to prioritize digital transformation risk falling behind competitors who have mastered the art of integrating tech with operations. Here’s why tech-savvy leadership is critical for the future of warehousing. The role of technology in modern warehousing Technology is reshaping warehousing, driving efficiency and accuracy at every level. From inventory management to real-time data analytics, advanced tools are streamlining operations and improving decision-making. Low-code platforms like Tecsys’ Itopia, IoT-enabled devices, robotics, and AI are no longer “nice-to-haves” — they’re essential for optimizing workflows and tackling unique operational challenges. They allow for a highly customized operation without the highly customized price tags, and the ability for continuous upgrades. These technologies allow warehouses to make smarter, faster decisions that directly impact the bottom line. Skills that define a tech-savvy manager Being tech-savvy isn’t just about understanding software — it’s about knowing what’s possible. A strong manager doesn’t need to master every aspect of a WMS but should have the awareness to collaborate effectively with IT teams. After all, IT can’t solve problems they don’t fully understand. Key skills include data literacy, metric analysis, and creative thinking. Tech-savvy managers leverage WMS tools as extensions of their physical workflows, utilizing technology to address bottlenecks, enhance efficiency, and drive performance. By understanding what their tools can do, managers can propose actionable solutions that align with their team’s operational realities. Implementing and managing change effectively Introducing new technology often sparks resistance, but tech-savvy managers know how to lead change effectively. The best leaders don’t shy away from the action — they test tools themselves, listen to frontline workers, and iterate based on real-world feedback. For example, a manager testing a new replenishment system might shadow a picker or replenisher to understand pain points firsthand. By getting hands-on, they not only identify potential improvements but also demonstrate to their teams that they’re committed to the process. Piloting new tools, gathering feedback, and leading by example are essential steps for reducing resistance and building trust. The best implementations I have seen are those where not only the warehouse management team shadows the users, but their IT counterparts also actively spend time on the warehouse floor. When IT spends time with users, it gives a unique perspective that drives creative and efficient solutions. The impact on warehouse performance and employee satisfaction Tech-savvy managers don’t just improve warehouse performance — they transform it. By simplifying processes, reducing errors, and enabling more innovative resource management, they unlock new levels of productivity and efficiency. Equally important is the effect on employees. When managers empower their teams to leverage technology, they foster a culture of innovation and collaboration. Workers are more engaged, less frustrated by inefficient processes, and more confident in their ability to contribute to the warehouse’s success. Over time, this leads to better retention, stronger team dynamics, and a future-ready operation. Embracing the future with tech-savvy leadership The future of warehousing belongs to those who invest in tech-savvy leadership. Managers who understand how to integrate technology with operations are the ones who will drive their businesses forward, adapting to market demands with ease. Warehouse operators must take action by assessing their leadership teams’ tech capabilities and providing ongoing training to bridge gaps. The path to operational excellence begins with forward-thinking managers who view technology not as a challenge but as an opportunity. Now is the time to embrace that future. About the Author Vee Srithayakumar is a product leader in warehouse management at Tecsys, driving innovation through AI-driven and advanced warehouse execution system initiatives. His contributions to the supply chain industry earned him recognition as a 2024 Supply & Demand Chain Executive “Pros to Know.”

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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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