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Optimizing Warehouse Efficiency: A Warehouse Manager’s Expert Guide to Waste Elimination
Published
2 ans agoon
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.
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Last Chance: Join the Webinar on AI, Component Sourcing, and the Future of Procurement
Published
1 jour agoon
22 juin 2026By
Electronic component sourcing is becoming one of the most important cost and risk challenges facing manufacturers.
Pricing remains opaque. Supplier quotes do not always reflect true market pricing. Internal purchase history may show what a company paid, but not whether that price was competitive.
At the same time, chips and components are increasingly tied to geopolitics, tariffs, AI infrastructure, defense demand, electrification, industrial automation, and supply chain resilience.
The webinar is tomorrow at 11 AM ET. Register now to join ARC Advisory Group’s discussion, The Hidden Cost of Component Sourcing — and How AI Is Fixing It, featuring Jim Frazer in conversation with Lytica CEO Martin Sendyk.
This is a practical conversation for procurement, supply chain, engineering, operations, and executive leaders who are trying to understand how component sourcing is changing.
Manufacturers need to control cost, protect supply, support product launches, and manage risk in a market where visibility is often limited. Overpayment can remain hidden. Component risk can appear too late. Engineering and procurement decisions can become locked in before teams have enough market intelligence to make the best sourcing choices.
Tomorrow’s webinar will examine why traditional approaches to component sourcing are under pressure and how manufacturers can use better intelligence to identify hidden cost, improve benchmarking, and manage sourcing risk more effectively.
Attendees will learn:
Why electronic component pricing remains difficult to benchmark
How hidden overpayment can persist inside normal procurement activity
Why supplier quotes, list prices, and internal history are not enough
How real transactional data can improve pricing visibility
Why geopolitics, AI demand, tariffs, electrification, and defense demand are changing the sourcing risk equation
How AI and sourcing intelligence can help procurement teams make better cost and risk decisions
The issue is no longer only whether a company can secure supply.
The issue is whether it can secure the right components, at the right price, with the right risk profile, early enough to influence the business outcome.
For many manufacturers, that requires a more transparent, data-driven, and intelligence-led sourcing model.
Register now for the ARC Advisory Group webinar with Jim Frazer and Lytica CEO Martin Sendyk before the session begins tomorrow at 11 AM ET.
Register for the Webinar
The Hidden Cost of Component Sourcing — and How AI Is Fixing It
Date: June 23, 2026
Time: 11:00 AM ET
Location: Online
Speakers: Jim Frazer, Vice President, ARC Advisory Group, and Martin Sendyk, CEO, Lytica
If your organization manages a significant electronic component spend, this webinar will help you understand how AI and transactional market data can expose hidden sourcing costs and turn procurement into a more proactive system of intelligence.
Register now to reserve your spot.
The post Last Chance: Join the Webinar on AI, Component Sourcing, and the Future of Procurement appeared first on Logistics Viewpoints.
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Weekly Supply Chain and Logsitics News Round Up (June 15th-18th 2026)
Published
4 jours agoon
19 juin 2026By
This week in logistics, the industry faces a pivotal shift as Transportation Management Systems evolve into ‘decision intelligence’ hubs, moving beyond basic routing to become the core operating brain of the supply chain. Meanwhile, operational complexity reaches new heights with the massive logistical undertaking of the 2026 FIFA World Cup, even as trade tensions show signs of cooling following the European Parliament’s approval of a landmark EU-US tariff relief deal. From record-breaking automation at Nestlé’s new California hub to the fluctuating volatility of global air freight rates, these developments underscore a sector increasingly defined by high-tech integration and rapid adaptation to global market forces.
The Leading Supply Chain and Logistics Stories of the Week:
TMS Is Becoming Less of a Routing Tool and More of a Decision Intelligence Layer Beyond Execution
The role of the Transportation Management System (TMS) is undergoing a major paradigm shift. While traditional evaluations still focus heavily on execution-level metrics—like route optimization, automated tendering, and freight audit capabilities—these features have essentially become table stakes. Moving forward, the true strategic value of a TMS lies in its evolution from execution software to “transportation decision infrastructure.” Rather than just completing transactions, next-generation platforms serve as the continuous decision-making layer of the supply chain. By drawing data from across the entire network, integrating external market signals, and resolving multi-functional bottlenecks, modern TMS solutions are transitioning into the core operating brain that synchronizes movement, cost, and service levels in real time.
The Logistics Issue: The Supply Chains Behind the World Cup
While most fans focus entirely on the action on the pitch, supply chain professionals are watching what might be the most complex logistical undertaking in sporting history: the 2026 FIFA World Cup. Spanning three host nations—the United States, Canada, and Mexico—the sheer scale of the tournament requires moving more than twenty million pounds of equipment, coordinated across 5,000 vehicles and millions of square feet of warehouse space. The challenge isn’t just massive volume; it’s the absolute lack of tolerance for delay or error across highly regulated international borders. Industry experts point out that success hinges on establishing a unified ecosystem in which freight forwarders, customs officials, and vendors collaborate in real time. Crucial to this effort are standardized product identification and cloud-based labeling networks, which ensure that every critical piece of equipment, food shipment, and medical supply is fully traceable and compliant with differing regional mandates—proving that at this scale, elite collaboration is the only way to avoid catastrophic bottlenecks.
Transatlantic Trade Relief: European Parliament Greenlights EU-US Tariff
In a major relief to transatlantic supply chain operators, the European Parliament has officially voted to implement the long-awaited trade agreement with the United States. Under the newly approved legislation, the EU will eliminate tariffs on all American industrial goods and grant preferential market access to key U.S. agricultural and seafood shipments. In return, the U.S. has agreed to cap import tariffs on European products at 15%—effectively averting threatened 25% tariff hikes on European-built vehicles. Importantly for logistics planners, the deal incorporates a “defensive toolbox” to mitigate long-term trade volatility, including a sunset clause set for late 2029, a safeguard mechanism to protect EU markets from disruptive import surges, and strict conditions that allow the EU to suspend tariff preferences by the end of 2026 if the U.S. fails to lower existing duties on European steel and aluminum derivatives.
Nestlé Opens Its Largest and Most Technologically Advanced Distribution Center in the U.S.
Nestlé USA has officially unveiled its new 700,000-square-foot distribution hub in Arvin, California. Equipped with a $330 million price tag, the state-of-the-art facility represents a critical step in the company’s broader $25 billion U.S. infrastructure upgrade, emphasizing a pivot toward leaner, automation-first supply chain workflows. The Arvin facility houses the largest Automated Storage and Retrieval System (ASRS) in Nestlé’s global network, operating alongside laser-guided vehicles, automated crane systems, and layer-picking robotics. This build marks a major shift from retrofitting existing spaces to intentionally designing high-tech capabilities directly into greenfield logistics layouts from day one. Designed to mitigate peak-season labor bottlenecks, upskill the frontline workforce, and run on 100% renewable electricity as a zero-waste site, the facility showcases how global leaders are leveraging heavy automation to establish flexible, resilient distribution networks that protect margins against ongoing labor and capacity constraints.
Air Freight Spot Rates Spike 41% YoY in May, but Relief Is Expected Soon
Global air cargo spot rates surged by 41% year-over-year in May, averaging $3.40 per kilogram, driven by persistent geopolitical disruptions, carrier fuel surcharges, and localized demand booms like semiconductor and data center equipment shipments. According to Xeneta data, spot rates from Northeast and Southeast Asia to North America jumped nearly 40% compared to earlier this year. However, the pricing pressure isn’t uniform; transatlantic lanes from Europe to North America actually saw a 26% decline over the same period. For procurement teams battling these elevated costs, there is a glimmer of light on the horizon. Long-term contract rates appear to have peaked in April, and as carriers restore capacity and the market enters its traditional summer lull, analysts predict that year-over-year spot rate comparisons will finally begin to cool down, offering much-needed breathing room for shippers who have been relying on short-term contract extensions.
Song of the week:
The post Weekly Supply Chain and Logsitics News Round Up (June 15th-18th 2026) appeared first on Logistics Viewpoints.
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Why Octave’s Austin Event Matters: From Asset Lifecycle Software to Intelligence at Scale
Published
6 jours agoon
17 juin 2026By
Octave Live OnTour Austin takes place at a consequential point in the evolution of the industrial software market. Asset-intensive organizations are under sustained pressure to improve capital project execution, asset reliability, operational resilience, safety, quality, cybersecurity, and workforce productivity. At the same time, they are being asked to make better use of data and apply AI in ways that are practical, governed, and operationally relevant.
This is the context in which Octave’s Austin event should be evaluated.
Octave, the software spin-off from Hexagon AB, brings together software assets across engineering, construction, geospatial intelligence, asset operations, quality, public safety, physical security, and industrial cybersecurity. Its Design, Build, Operate, and Protect framework provides a clear structure for organizing those capabilities around the industrial asset lifecycle.
However, the strategic significance of the event is not limited to Octave’s portfolio structure. The more important issue is what Octave’s positioning indicates about the broader direction of industrial software.
The market is shifting from digitized workflows toward intelligence at scale.
Industrial Software Is Moving Beyond Functional Digitization
For much of the past two decades, industrial software investment has centered on functional digitization. Engineering teams adopted design, modeling, analysis, and engineering information management tools. Construction teams deployed project controls and field execution systems. Operations teams invested in EAM, APM, optimization, and reliability applications. Quality, safety, physical security, and cybersecurity functions developed their own specialized technology environments.
These investments created meaningful value within individual domains. But they also reinforced a long-standing structural problem: industrial work is highly interconnected, while the supporting software environment often remains fragmented.
A design change can alter construction cost and schedule. Construction execution quality can affect commissioning performance. Poor handoff from construction to operations can increase maintenance burden. Maintenance backlog can elevate safety and compliance risk. A cybersecurity incident can become an operational disruption. A public safety event may require geospatial, security, asset, and operational context at the same time.
This is the gap that lifecycle intelligence seeks to address.
Lifecycle Intelligence Requires Context Across the Asset Lifecycle
Octave’s Design, Build, Operate, and Protect framework is meaningful because it reflects how industrial assets are planned, built, used, maintained, protected, and improved over time.
In the Design domain, Octave can address engineering, modeling, analysis, information management, and geospatial intelligence. In Build, the portfolio extends into construction, supply chain management, and project performance. In Operate, the focus expands to operations optimization, asset performance, enterprise asset management, quality, compliance, and risk. In Protect, Octave’s positioning includes public safety, physical security, and industrial cybersecurity.
Individually, these are established industrial software categories. Collectively, they suggest a broader strategic direction: the use of software to preserve, connect, and operationalize context across the asset lifecycle.
That is where the Austin event becomes important. Customers and partners should look for evidence that Octave is moving beyond portfolio aggregation toward a more integrated model of lifecycle intelligence.
Intelligence at Scale Depends on Integration, Data, and Workflow Relevance
The phrase “intelligence at scale” should be interpreted operationally, not rhetorically. In industrial environments, intelligence at scale means that software can connect relevant data, apply domain context, and support better decisions across complex workflows.
This requires more than analytics dashboards. It requires software that can help users understand the implications of decisions across functions. It also requires a data foundation that connects engineering data, project execution status, asset histories, maintenance records, geospatial information, quality events, safety incidents, and cybersecurity signals.
AI increases the importance of this foundation. AI capabilities will have limited enterprise value if they are disconnected from operational systems and industrial context. The more material opportunity is AI that is embedded in real workflows and supported by trusted domain data.
For Octave, the strategic question is whether its portfolio can support AI-enabled decision-making across the asset lifecycle, rather than isolated AI features within individual applications.
The Event Should Be Assessed as a Roadmap Signal
Buyers should treat Octave Live OnTour Austin as a roadmap signal.
The first area to assess is integration. Octave’s portfolio breadth creates potential value, but customers will need clarity on how the company intends to connect products and workflows over time. Important indicators include shared data models, workflow orchestration, user experience consistency, API strategy, and cross-domain analytics.
The second area is AI. Customers should listen for specific use cases, not general AI messaging. Relevant examples could include project risk identification, asset performance optimization, maintenance prioritization, quality exception management, safety response, cyber risk monitoring, or engineering decision support. The key issue is whether AI is being tied to operational outcomes.
The third area is ecosystem fit. Industrial organizations rarely standardize on a single vendor across the full technology landscape. Octave will need to clarify how its offerings interact with ERP, EAM, APM, MES, PLM, project controls, cybersecurity, and analytics environments. The value proposition must be additive without increasing architectural complexity.
The fourth area is sequencing. Broad portfolios require disciplined execution. A credible roadmap should identify where Octave will focus first, what integration steps matter most, and how customers should think about value realization over time.
Broader Market Implications
Octave’s Austin event matters because it reflects a larger shift in industrial software.
The next stage of the market will not be defined solely by applications that digitize individual workflows. It will be defined by platforms and architectures that connect operational context across functions. This does not mean every customer will consolidate around a single software suite. Industrial technology environments will remain heterogeneous. But the strategic requirement for connected data, workflow continuity, and decision support will continue to intensify.
AI will accelerate this trend. Effective AI depends on relevant context. If industrial data remains trapped in disconnected systems, AI will be limited to narrow productivity assistance. If data and workflows are connected, AI can support higher-value decisions involving risk, reliability, performance, safety, and resilience.
That is why lifecycle intelligence is becoming an important industrial software concept. It reflects the need to move from systems that record activity to systems that help organizations understand and act on operational complexity.
ARC Advisory Group Perspective
Octave has a credible opportunity to participate in this market transition. The company has meaningful software assets across multiple industrial domains, and its Design, Build, Operate, and Protect framework provides a practical way to organize the portfolio.
The central question is execution. Octave will need to demonstrate that its portfolio can become more than a set of adjacent capabilities. Customers will expect integration clarity, practical AI use cases, ecosystem openness, and a roadmap that connects near-term value to a longer-term lifecycle intelligence strategy.
For buyers, the Austin event should be used to evaluate roadmap direction and strategic fit. For partners, it should clarify Octave’s intended role in the industrial software ecosystem. For the broader market, it is another indication that industrial software is moving toward connected intelligence at scale.
The companies that define this next phase will not simply digitize industrial work. They will connect context across the asset lifecycle and convert that context into better decisions.
The post Why Octave’s Austin Event Matters: From Asset Lifecycle Software to Intelligence at Scale appeared first on Logistics Viewpoints.
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