Connect with us

Non classé

Optimizing Warehouse Efficiency: A Warehouse Manager’s Expert Guide to Waste Elimination

blog

Published

on

Optimizing Warehouse Efficiency: A Warehouse Manager’s Expert Guide To Waste Elimination

In the dynamic landscape of modern supply chains, one of the key challenges is the efficient management of resources to eliminate waste and enhance overall productivity. In this article, we will delve into strategic ways for warehouse managers to eliminate waste, with a focus on not only optimizing the use of cartons and packing, but labor resources and warehouse space as well.

Carton and Packing Optimization

Carton optimization is a critical aspect of warehouse management, as it directly impacts shipping costs, storage space, and overall efficiency. Packing efficiently is essential for maximizing storage capacity and minimizing waste in the warehouse. One effective method to optimize packing is the standardization of carton sizes. By collaborating closely with suppliers and carriers, managers can establish uniform carton dimensions that minimize the need for excessive packaging materials. Standardized carton sizes also facilitate more efficient stacking and storage within the warehouse, reducing space utilization and improving overall operational flow. Keep in mind though, that standardizing cartons is a good point for efficiency of stacking and packing, but it can be counter to being efficient on carton space. You may be giving up some carton space efficiency for the benefits of stacking, storing, and shipping efficiencies.

Another key strategy is right-sizing cartons to match the specific dimensions of the products being shipped. Tailoring carton sizes in this way eliminates unnecessary void space within packages, which not only optimizes space but also minimizes the risk of product damage during transit. This attention to detail in packaging design ensures that products are securely packed, leading to safer deliveries and reducing potential costs associated with damaged goods. Solutions to these types of problems are incredibly complex and must lean on a variety of modern technologies and know-how for help. Lucas Systems has partnered with Carnegie Mellon University on research focused on developing new and innovative ways to reduce distribution center and transportation waste by optimizing the way packing and packaging of multiple items in a single order is executed.

Always looking to innovate, Amazon has created a durable, weather-resistant paper that molds to the shape of a package, aiming to reduce waste. A sensor identifies items, many of which were traditionally shipped in boxes and redirects them to the new packaging system. The machine then trims a paper bag to match the exact dimensions of the item, minimizing the empty space around it.

This focus on packaging material efficiency is crucial for both environmental and economic sustainability. With 90% of items shipped in the U.S. being packaged in cardboard, adopting eco-friendly and cost-effective materials, such as recycled cardboard or reusable packaging, warehouses can significantly reduce waste. These materials not only contribute to a greener supply chain but also offer long-term cost savings, making the entire packing process more efficient and sustainable.

Warehouse Space Optimization

Real-time monitoring and analytics play a critical role in maintaining warehouse efficiency. By leveraging advanced technologies, warehouse managers can gain insights into space utilization and identify potential bottlenecks before they become problematic. This proactive approach allows for timely adjustments, ensuring that space is optimized, and operations run smoothly. The ability to make data-driven decisions in real-time is invaluable for maintaining a high level of operational efficiency.

This leads us to the idea of Dynamic Slotting, an essential strategy for space optimization. Product slotting is a complex problem. It involves many input factors and many goals (which are sometimes at odds with each other). Traditional slotting solutions require customized models, extensive engineering, measurement, and data collection. Dynamic Slotting involves the use of software and algorithms to perform velocity and affinity analysis, in a real-time, ever adapting fashion, through the use of artificial intelligence and machine learning. By conducting a velocity analysis, the software can categorize products based on their demand and importance. This review can also include affinity analysis, or the odds of items being picked together, parallel to velocity analysis. High-demand items, or “fast movers,” or even frequent partners, can be strategically placed in easily accessible locations within the warehouse. In parallel to the high velocity items, items with higher affinity can be placed near those to minimize travel when they are associated.

These placements not only reduce the time spent searching for these items but also minimizes congestion in high-traffic areas, leading to smoother and quicker order fulfillment processes. By organizing products based on their popularity or seasonality, warehouse managers can ensure that frequently picked items are placed in the most accessible locations. This reduces the time and effort required for order fulfillment, as workers spend less time traveling through the warehouse to pick items. Dynamic Slotting also empowers flexibility and adaptability, allowing for more real-time moves and enabling the warehouse layout to adjust to changes throughout the year.

Another key strategy is the implementation of cross-docking. Cross-docking streamlines the flow of goods by transferring them directly from the receiving dock to outbound shipping, effectively bypassing the need for storage. This approach reduces the need for extensive storage space and shortens the order fulfillment cycle, ensuring that products move swiftly through the supply chain. As a result, inventory is kept lean, and warehouse space is utilized more efficiently.

Finally, the efficient use of vertical space is often an underutilized opportunity in warehouse management. Investing in adjustable shelving and racks can maximize the use of available vertical space, allowing warehouses to store more inventory without expanding their footprint.

Labor Optimization

Analyzing order picking patterns and creating optimized pick paths can significantly reduce the travel time for warehouse staff. This not only enhances efficiency but also minimizes the wear and tear on equipment.

For example, using software, after batches are created, multiple algorithms can be applied to determine an optimized path for the user to take through the warehouse to complete their work. The algorithms consider aisle directions (one-way aisles, for example), base item designations, and other factors to determine the most efficient pick path.

Also, instead of having workers pick one order at a time, multi-stage picking can deliver labor and process optimization benefits. Instead of a single picker handling an entire order from start to finish, different stages are handled by specialized teams or automated systems. This method enhances efficiency by allowing simultaneous processing of multiple orders, reduces travel time within the warehouse, and optimizes labor by assigning tasks based on skill levels or equipment capabilities. The result is faster order fulfillment, reduced errors, and improved scalability in high-volume operations.

Task interleaving in a warehouse also optimizes labor resources by integrating multiple types of tasks into a worker’s daily routine, rather than having them focus on a single task at a time. For instance, instead of assigning a worker solely to picking orders or restocking shelves, task interleaving allows them to perform these tasks interchangeably based on real-time demand and proximity. This dynamic allocation of tasks minimizes idle time and maximizes productivity by ensuring that workers are always engaged in meaningful work.

By interleaving tasks, such as combining order picking with replenishment, workers can handle multiple tasks on a single trip through the warehouse. This reduces unnecessary travel, one of the most significant sources of waste in warehouse operations, and ensures that workers are consistently productive, even during slower periods. Task interleaving also helps balance workloads across the workforce, preventing bottlenecks in one area while workers in another area remain underutilized.

Effectively implementing task interleaving generally necessitates the use of specialized software or a Warehouse Management System (WMS), because of their capability to dynamically assign and prioritize tasks using real-time data, ensuring that the most efficient paths and sequences are followed throughout the warehouse.

In closing, by focusing on carton optimization, packing efficiently, and maximizing warehouse space, and labor resources, managers can significantly reduce costs, enhance sustainability, and ensure a seamless flow of goods through the warehouse. Embracing technology, collaborating with suppliers, and implementing dynamic strategies are key steps toward achieving waste elimination and creating a lean, agile, and efficient warehouse ecosystem.

Ben Smeland is a Senior Software Developer with Lucas Systems, leveraging over 19 years of software development experience to challenge and innovate against software architectures to promote clarity, performance, and sustainability.

With experience as a full-stack developer, software architect, and project manager, Ben has served in almost every capacity in the software industry, engaging with internal teams and customers to bring inventive, sustainable solutions to complicated business problems.

The post Optimizing Warehouse Efficiency: A Warehouse Manager’s Expert Guide to Waste Elimination appeared first on Logistics Viewpoints.

Continue Reading
Click to comment

You must be logged in to post a comment Login

Leave a Reply

Non classé

What a Return to the Red Sea Could Mean for the Container Market

Published

on

By

What a Return to the Red Sea Could Mean for the Container Market

November 26, 2025

Blog

As the fragile but still-in-place Israel-Hamas ceasefire nears the two-month mark, and with the Houthis declaring an end to attacks on passing vessels, there is more and more anticipation that the long-awaited return of container traffic to the Red Sea may be coming soon.

Though Maersk maintains it has not set a date, the Suez Canal Authority stated that Maersk will resume transits in early December. ZIM’s CEO recently stated that a return in the near future is increasingly likely, and CMA CGM is reportedly preparing for a full return in December.

Operational Impact

The shift of most of the 30% of global container volumes that normally transit the Suez Canal away from the Red Sea and around the Cape of Good Hope almost exactly two years ago added seven to ten days and thousands of nautical miles to Asia – Europe journeys and to some Asia – N. America sailings as well.

The return of container traffic to the shorter Suez route will result in the sudden early arrival of these ships, which will mean significant vessel bunching and congestion at already persistently congested European hubs. This congestion will cause delays and absorb capacity which could push container rates up on the affected lanes, and possibly beyond.

The shift back through the Suez Canal may initially keep some of the typically lower volume ports in Europe that have become transhipment centers during the Red Sea crisis, like Barcelona, busy while carriers may omit port calls at some of the congested major hubs. But after the unwind, these ports, as well as African ports that have been used as refuelling stops during the last two years, will see port calls decline.

Carriers have plans for a gradual phase in of the transition back to the Red Sea, with smaller vessels starting to transit first. This approach would still cause vessel bunching, but would be aimed at minimizing the impact of the reset as much as possible.

But some carriers are skeptical that an orderly phase-in will happen, as they expect pressure from customers who will want a return to the shorter route as quickly as possible. Analysis from Sea Intelligence suggests that the more gradual the transition, the less disruptive it will be, while the faster the return the more disruptive it will be during the up to two months it will take for schedules to return to normal.

Ocean expert Lars Jensen also notes that a return during the lead up to Lunar New Year would coincide with an increase in demand, and would put more pressure on ports and rates than if the transition takes place post-LNY when demand is typically weak. With carriers signalling the shift will begin in December and pre-LNY demand probably picking up in mid-January next year, it seems likely the two will coincide.

Implications for Capacity – and Rates

Red Sea diversions were estimated to have absorbed about 9% of global container capacity by keeping ships at sea for longer and – with longer journeys meaning vessels would arrive back at origins days behind schedule – via carriers adding extra vessels to services in order to maintain planned weekly departures.

This drain on capacity caused Asia – Europe rates to more than triple and transpacific rates to more than double in the two months from the time the diversions began to just before Lunar New Year of 2024. And though rates moved up and down along with seasonal changes in demand, the capacity drain pushed East-West rates up to 2024 highs of $8,000 – $10,000/FEU and set a highly elevated floor of $3,000 – $5,000/FEU during low demand periods that year.

But even with Red Sea diversions continuing to absorb capacity in 2025, continued fleet growth through newly built vessels entering the market has meant that the container trade has already become significantly oversupplied.

As such, rates on these lanes – even before the capacity absorbed by diversions has re-entered the market – have consistently been significantly lower than in 2024 even during months when volumes have been stronger, with prices on some lanes reaching 2023 levels for a span in early October. Recent carrier struggles maintaining transpacific GRIs point to this challenge already.

Even with Red Sea diversions continuing and even during months in 2025 with stronger year on year volumes, capacity growth has meant rates in 2025 have been lower than in 2024.

Yes, the initial congestion and delays caused by the transition back to the Suez Canal will at first put upward pressure on rates for Asia-Europe containers and probably to a lesser degree on the transatlantic lanes as well. If the congestion ties up enough capacity or impacts operations at Far East origins, the rate impact could spread to the transpacific as well. As noted above, if the return coincides with the lead-up to LNY, it will have a stronger impact on rates as there will be pressure from the demand side as well.

But once the congestion unwinds and container flows and schedules stabilize the shift will ultimately release more than two million TEU of container capacity back into the market. This surge will put even more downward pressure on rates and increase the challenge of effectively managing capacity for carriers seeking to keep vessels full and rates profitable in 2026.

Judah Levine

Head of Research, Freightos Group

Judah is an experienced market research manager, using data-driven analytics to deliver market-based insights. Judah produces the Freightos Group’s FBX Weekly Freight Update and other research on what’s happening in the industry from shipper behaviors to the latest in logistics technology and digitization.

Put the Data in Data-Backed Decision Making

Freightos Terminal helps tens of thousands of freight pros stay informed across all their ports and lanes

The post What a Return to the Red Sea Could Mean for the Container Market appeared first on Freightos.

Continue Reading

Non classé

Transpac ocean rates fizzle; Red Sea return coming soon? – November 25, 2025 Update

Published

on

By

Transpac ocean rates fizzle; Red Sea return coming soon? – November 25, 2025 Update

Discover Freightos Enterprise

November 25, 2025

Blog

Weekly highlights

Ocean rates – Freightos Baltic Index

Asia-US West Coast prices (FBX01 Weekly) decreased 32% to $1,903/FEU.

Asia-US East Coast prices (FBX03 Weekly) decreased 8% to $3,443/FEU.

Asia-N. Europe prices (FBX11 Weekly) decreased 1% to $2,457/FEU.

Asia-Mediterranean prices (FBX13 Weekly) increased 6% to $2,998/FEU.

Air rates – Freightos Air index

China – N. America weekly prices decreased 2% to $6.50/kg.

China – N. Europe weekly prices decreased 1% to $3.97/kg.

N. Europe – N. America weekly prices increased 1% to $2.33/kg.

Analysis

Despite higher tariffs since early this year, US retail sales have proved resilient and are expected to grow through the holiday season. The solidifying tariff landscape is nonetheless facing destabilizing forces like recent China-Japan tensions, and the US Supreme Court’s pending decision on the legality of Trump’s IEEPA-based tariffs.

But the White House is signalling it is already taking steps to ensure that a SCOTUS loss will not open a low tariff window. So, if consumer spending remains strong, and the status quo of the trade war holds up, the US could enter a restocking cycle in 2026 as frontloaded inventories wind down. This restocking could mean stronger freight demand than some have anticipated for next year.

On the freight supply side though, there is more and more discussion of container traffic’s coming return to the Red Sea as the fragile Israel-Hamas ceasefire remains in effect. And while most carriers are not offering a timeline, ZIM’s CEO recently stated that a return in the near future is increasingly likely.

The shift of most of the 30% of global container volumes that normally transit the Suez Canal away from the Red Sea and around the Cape of Good Hope almost exactly two years ago added seven to ten days and thousands of miles to Asia – Europe journeys and to some Asia – N. America sailings as well.

The return of container traffic to the shorter Suez route will result in the sudden early arrival of these ships, which will mean significant vessel bunching and congestion at already persistently congested European hubs. This congestion will cause delays and absorb capacity which could push container rates up on the affected lanes, and possibly beyond.

Carriers have plans for a gradual phase in of the transition back to the Red Sea, with smaller vessels starting to transit first. This approach would still cause vessel bunching, but would be aimed at minimizing the impact of the reset as much as possible.

But some carriers are skeptical that an orderly phase-in will happen, as they expect pressure from customers who will want a return to the shorter route as quickly as possible. Analysis from Sea Intelligence suggests that the more gradual the transition, the less disruptive it will be, while the faster it is the more disruptive it will be, and the more pressure it will put on freight rates during the up to two months it will take for schedules to return to normal.

Ocean expert Lars Jensen also notes that a return during the lead up to Lunar New Year would coincide with an increase in demand, and would put more pressure on ports and rates than if the transition takes place post-LNY when demand is typically weak.

The capacity absorbed through Red Sea diversions pushed East-West rates up to highs of $8,000 – $10,000/FEU in 2024 and set a highly elevated floor of $3,000 – $5,000/FEU during low demand periods that year. But even with Red Sea diversions still in place this year, rates on these lanes have consistently been significantly lower than last year, with prices on some lanes reaching 2023 levels for a span in early October.

The transition back to the Suez Canal – be it more or less chaotic – will ultimately release more than two million TEU of container capacity back into the market. This surge will put even more downward pressure on rates and increase the challenge of effectively managing capacity for carriers seeking to keep vessels full and rates profitable.

The current overcapacity on the East-West lanes is the main reason that carriers’ November transpacific GRIs which had pushed West Coast rates up by $1,000/FEU this month to about $3,000/FEU have now fizzled.

Asia – N. America West Coast prices fell 32% last week to $1,900/FEU with daily rates this week down another $100 so far, but prices remain above the $1,400/FEU low for the year hit in early October. Last week’s vessel fire at the Port of LA does not seem to have had an impact on prices as operations have quickly recovered. Rates to the East Coast fell 8% to $3,400/FEU last week but are at $3,000/FEU so far this week, about even with levels in early October before these set of GRI introductions.

Meanwhile, October and November’s GRIs on Asia-Europe lanes have stuck, with rates to Europe and the Mediterranean both 40% higher than in early October at $2,500/FEU and $3,000/FEU respectively. These rate gains may be surviving on aggressive blanked sailings on these lanes.

Carriers are planning additional GRIs for December aiming for the $3k-$4k/FEU level as they continue to reduce capacity – with an announced labor strike in Belgium likely to help absorb some supply – but there are signs that these increases may not take.

In air cargo, peak season demand is driving rates up and should keep doing so for the next couple weeks. Freightos Air Index data show ex-China rates remaining strong at about $6.50/kg to N. America and $4.00/kg to Europe last week. Demand out of S. East Asia has grown significantly during this year’s trade war, with rates also elevated on these lanes at $5.40/kg to the US and $3.50/kg to Europe.

Discover Freightos Enterprise

Freightos Terminal: Real-time pricing dashboards to benchmark rates and track market trends.

Procure: Streamlined procurement and cost savings with digital rate management and automated workflows.

Rate, Book, & Manage: Real-time rate comparison, instant booking, and easy tracking at every shipment stage.

Judah Levine

Head of Research, Freightos Group

Judah is an experienced market research manager, using data-driven analytics to deliver market-based insights. Judah produces the Freightos Group’s FBX Weekly Freight Update and other research on what’s happening in the industry from shipper behaviors to the latest in logistics technology and digitization.

Put the Data in Data-Backed Decision Making

Freightos Terminal helps tens of thousands of freight pros stay informed across all their ports and lanes

The post Transpac ocean rates fizzle; Red Sea return coming soon? – November 25, 2025 Update appeared first on Freightos.

Continue Reading

Non classé

How AI Is Driving the Future of Industrial Operations and the Supply Chain

Published

on

By

How Ai Is Driving The Future Of Industrial Operations And The Supply Chain

ARC Industry Leadership Forum • Orlando, Florida
February 9–12, 2026 • Renaissance Orlando at SeaWorld

Artificial intelligence is reshaping how industrial organizations run their operations and supply chains. The shift is real. The early experiments are gone. Today, companies are redesigning their planning, logistics, reliability, sourcing, and production workflows around systems that can think, react, and coordinate.

At ARC Advisory Group, we’re seeing this change accelerate every quarter. AI is moving from a standalone project to the connective tissue between operational systems. It’s improving how energy is consumed, how materials flow, how assets behave, and how teams respond to uncertainty.

This February, leaders from across the world will gather in Orlando to break down where AI is creating value and what comes next.

Event Details
Renaissance Orlando at SeaWorld
6677 Sea Harbor Drive, Orlando, FL 32821
February 9–12, 2026
Event link: https://www.arcweb.com/events/arc-industry-leadership-forum-orlando

More than 200 colleagues are already registered, including Conrad Hanf and a broad mix of executives, operations leaders, and technologists.

Why AI Matters Right Now

AI gives industrial organizations three capabilities they’ve never had before.

Real-time awareness.
Factories, yards, pipelines, fleets, and distribution nodes are producing enormous amounts of data. AI helps cut through that noise. It identifies what matters, when it matters, and why. The result is faster decisions and fewer surprises.

Coordination across functions.
Production affects logistics. Maintenance affects throughput. Sourcing affects lead time. AI lets these domains share context and act together instead of waiting for a meeting or a spreadsheet adjustment. Decisions that once took a day now happen instantly.

Pattern recognition at scale.
AI sees the earliest signals of asset degradation, demand shifts, port delays, or supply risk. It doesn’t wait for a problem to become a crisis. It alerts teams early and recommends actions with enough lead time to matter.

What Leaders Are Focusing On

Across our research and briefings, the same themes keep rising to the surface.

AI-driven maintenance and reliability.
Predictive models are becoming the default. They diagnose root causes, calculate the impact of failure, and help schedule work when it makes operational sense.

Modern planning and scheduling.
Forecasts now incorporate external signals, real-time plant conditions, and multi-site interactions. Planners are starting to work with continuously updated recommendations instead of static plans.

Autonomous supply chain operations.
AI agents are beginning to negotiate with carriers, re-route shipments, rebalance inventory, and adjust sourcing strategies. This isn’t sci-fi. It’s quietly happening in live networks.

Graph intelligence.
Industrial networks are connected by thousands of relationships. Knowledge-graph models help organizations understand those connections and trace how one event cascades across an entire operation.

Data discipline.
AI’s performance depends on clean, harmonized data across ERP, MES, historians, WMS, TMS, and supplier systems. Many companies are now tackling this foundational work head-on.

Human and AI collaboration.
The most successful organizations aren’t automating people out. They’re giving operators, planners, and engineers AI tools that amplify experience and judgment.

Why Attend the ARC Industry Leadership Forum

The Forum is where these shifts come together. Attendees will see:

• Real-world case studies from global manufacturers, logistics leaders, and utilities
• Demonstrations of AI-enabled control towers and reliability platforms
• Deep-dive sessions on agent-based systems, context management, RAG assistants, and graph reasoning
• Roundtable conversations with peers facing the same operational pressures
• Practical discussions on governance, cybersecurity, workforce roles, and measurable ROI

This event is built for leaders who want clarity, validation, and a realistic roadmap for scaling AI across the industrial value chain.

A Turning Point for Industrial Operations

AI is changing the fundamentals of how materials move, how assets perform, how demand is met, and how decisions get made. The organizations that learn to use this intelligence well will operate with more resilience, more predictability, and less friction.

The ARC Industry Leadership Forum is the best place to understand what this looks like in practice and how to prepare your organization for it.

Join Us in Orlando

If your role touches operations, supply chain, engineering, logistics, maintenance, or industrial strategy, this gathering will be well worth your time.

Reserve your seat:
https://www.arcweb.com/events/arc-industry-leadership-forum-orlando

We hope to see you there.

The post How AI Is Driving the Future of Industrial Operations and the Supply Chain appeared first on Logistics Viewpoints.

Continue Reading

Trending