HOW DCS ARE REDEFINING EFFICIENCY
to get a job somewhere else or will they stay with you? What can you do with automation to help you retain labor?” The future holds the introduction of increasingly more automated and semi-automated systems, Friedrich expects. “We will see more incremental automation,” he says. “Companies may not automate the full warehouse, but it’s a step in that direction.” Distribution centers are among the links in the supply chain that are benefiting from access to more data— and those benefits will grow, allowing for smarter, more informed management of facilities, Friedrich says. “Collecting more data is one big benefit of automated systems,” he says. “We will start to see more warehouses adopt the software and infrastructure to manage and make decisions from all that data.” Improving efficiencies in DCs does not always involve sophisticated technology or innovative strategic thinking. Sometimes, it’s more about common sense, Friedrich says. “I was in a warehouse where workers had to walk huge distances across the facility,” he recalls. “They had forklifts, but not everyone is licensed to use a forklift and you’re not supposed to carry
passengers on them. So the company let workers drive around in golf carts. That was a simple but effective way to reduce the number of steps workers were taking.” Here’s how three leading companies help DCs operate on a higher level, using tech-based tools to tackle challenges and boost efficiencies. Taming the “Ugly” Package: Engineering Innovation’s Secret to Smooth Transitions The explosive growth of ecommerce has led to a range of fresh challenges, including the increasing prevalence of “ugly” packages. These packages— such as polybags, underweight or oversized parcels, and other “outside the box” items—often trip up traditional sorting systems unaccustomed to such variability. “In a traditional setup, the system can’t handle when one of these ugly packages hits the line,” says Don Caddy, CEO of Engineering Innovation. “So someone has to pull it, sort it, and possibly give it a second or manual pass. That slows down everything and takes up manpower, which we’re already struggling to get in the door and keep.” Consequently, Engineering Innovation has created a new divert
module for its Chameleon SLAM solution to contend with those troublesome packages. With the new module, “those items stay in the flow,” Caddy says, leading to fewer disruptions and smoother operations across the board. “We created a Pop-Up Shuttle Divert with minimal gaps between rollers, which means shifting and crushed polybags can no longer get snagged, ensuring a more consistent and smoother downline,” Caddy says. An effective introduction of new automation tools to the workers who will use them is critical to maximizing the value of those tools, and it is too often overlooked, he says. “If you don’t manage change well, you will have problems,” Caddy notes. “Workers get anxious and tend to assume the worst. Productivity drops despite all you’ve invested in new technology— nothing goes as you had hoped. That’s a communication problem. “On the other hand, if you take the time to explain what’s happening, involve your teams, and show them how the changes support their work, they’ll usually get behind it,” he adds. “Most people want to do a good job. They just need to know they’re not being left behind.” Start Early The first step is to get people involved early in the process. “Don’t just drop new systems on them and expect it to go well,” Caddy says. “People need to understand what’s coming, why it’s happening, and how it will help them. “Years ago, we had a customer whose floor operator thought the install of our machines meant he’d be out of work,” he says. “But through involving him in the process, he’s now the one who shows new hires how to run the SLAM line. It’s about ownership. When people feel like they’re part of the solution, the transition goes smoother.” Engineering Innovation spends a lot of upfront time ensuring the rollout of its
Engineering Innovation provides automated sorting, weighing, and routing systems that streamline material handling and reduce manual labor in distribution centers.
50 Inbound Logistics • November 2025
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