With the completion of the hypercare phase, KiK reports an entirely positive outcome: a structured, collaborative implementation, in-depth process knowledge, and a smooth go-live — both in Poland and Slovakia. Together, the two modern logistics centres form the backbone of the supply network for over 4,200 stores across 14 European countries.

The implementation of LFS was not just a technical challenge, but above all a collaborative project that crossed national borders. The central logistics team in Bönen, local staff on site, the SAP team, and EPG’s supply chain specialists worked closely together in a tightly coordinated effort. The excellent alignment among all parties involved was particularly praised. “The way the go-live was executed on site — it was truly first-class,” emphasized Michael Frölich, Managing Director of KiK Logistik GmbH. “The project team was exceptionally well-prepared, communicated as equals, and was consistently solution-oriented.”

142,000 Picks per Day

Kostolné Kračany demonstrates what modern warehouse logistics can achieve. Covering 46,000 square metres and offering around 40,000 pallet spaces, the LFS system manages all processes— from chaotic warehousing with an integrated FIFO principle to precise inventory traceability. The average daily throughput is 112,000 picks, with a record high of 142,000 picked units in a single day. In addition to textiles, the facility also handles seasonal non-food items such as decorations and toys. Specialized areas support the storage of hazardous materials and temperature-sensitive products like confectionery and beverages. Modern mobile data entry (MDE) devices and tablets are used throughout the facility, ensuring smooth process integration and transparent quality control from goods receipt to shipping.

Unified IT Structures as a Foundation for Scalability and Efficiency

With the implementation of LFS in Poland and Slovakia, KiK is pursuing a clear digital strategy: standardizing processes, harmonizing IT structures, and integrating new locations more quickly. Integration with the central SAP ERP system was achieved via standardized interfaces. Numerous custom extensions, such as for managing external warehouses or handling complex picking logic, highlight the system’s flexibility. A key success factor was the well-designed training concept. Employees were prepared for the new LFS using a hands-on approach in a test system. Lessons learned from the Polish rollout were deliberately applied to the implementation in Slovakia — an excellent example of effective knowledge transfer.

“The successful implementation of LFS at two international sites is the result of exceptionally close and trusting collaboration,” says Alain Linder, Team Lead Project Management Consulting at EPG. “Strong process knowledge on both sides, clear communication, and a shared goal made this project a true model for success.”

At KiK Logistik’s headquarters in Bönen, preparations for the next expansion phase are already underway. In the future, LFS will also control a fully automated high-bay warehouse with pallet conveyor technology at that location.

Future-Oriented: Real-Time Data, Transparency, and Paperless Processes

After going live, KiK continues to work closely with EPG to further develop its digital logistics landscape. Already today, the analytics tool TIMESQUARE provides meaningful real-time KPIs on pick times, warehouse utilization, and inventory transparency — an essential foundation for data-driven optimization.

The next milestone is the introduction of a digital delivery note. Currently, a physical packing list is still included in each shipment, but going forward this step will be completely paperless, from goods receipt to shipping. “With LFS, we haven’t just implemented a powerful warehouse management system — we’ve created a future-ready platform that evolves with our needs, both technically and operationally,” summarizes Frölich.

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Limited visibility with Blind warehouses

Blind warehouses are characterised by limited visibility into operations. Inventory counts may be outdated, workflows are manual, and decisions rely on human guesswork or historical trends rather than real-time insights. Why Blind warehouses fall behind:

Inventory inaccuracies: 46% of small to medium sized warehouses report that inaccurate inventory counts cause major fulfilment delays.
Lost productivity: Employees spend unnecessary hours locating stock or manually inputting data.
Delayed decisions: Without a clear operational picture, response times to disruptions are slow.
Cost inefficiencies: Overstocking or stockouts often occur due to poor forecasting and limited data.
Fragmented data: Warehouses often gather data in pieces, leading to disconnected insights that fail to represent the full picture.

The reality is clear: a lack of visibility is no longer sustainable. As customer expectations around speed and accuracy rise, blind decision-making becomes a liability.

What does it mean to become an Observable warehouse?

An Observable warehouse collects and records real-time data from all parts of its operations. This includes: Inventory movement and placement; Autonomous robot paths and performance; Warehouse environmental conditions; Inbound/outbound logistics and cycle times; Labour allocation and productivity.

Being observable doesn’t require full automation overnight. It means implementing systems that can provide visibility through sensors, IoT devices, AMRs (Autonomous Mobile Robots), computer vision, or digital twin platforms. For example, Ziegler selected Dexory to provide a scalable, reliable solution capable of operating seamlessly within the warehouse’s existing infrastructure. The deployment of DexoryView has delivered rapid and measurable value for Ziegler’s UK operations, including:

Faster stock recovery and fewer errors: The team is now able to quickly locate missing pallets, detect mispicks early, and address labelling or placement errors in real time – without halting operations. End of costly shutdowns for stock takes: Where full stock takes once required four days and weekend shifts, inventory is now continuously monitored – eliminating the need for disruptive audits and manual reconciliations.

‍The benefits of visibility

Becoming an Observable warehouse is the foundation for all other advancements. Here are several benefits:

Faster, smarter decisions: Managers gain immediate insights to prioritise tasks or reroute workflows.
Increased productivity: Time spent searching, scanning, and checking can be replaced with actionable data.
Reduced waste and errors: Real-time data reduces the risk of duplication, overstocking, or misplaced inventory.
Foundation for AI and automation: Visibility enables the implementation of intelligent systems that require real-time data to operate effectively.

For example, DCL Logistics has realized significant operational gains since deploying DexoryView:

14% increase in pallet location accuracy: With more precise data, the company has improved inventory reliability, reducing errors and improving fulfillment speed.
10x faster inventory counting: Compared to previously trialled drone-based systems, DexoryView delivers a tenfold increase in the speed of inventory counts – without disruption or downtime.
16 hours of labour saved per day: Eliminating manual inventory checks has freed up staff to focus on high-value strategic initiatives, such as warehouse space optimization and customized projects for clients.

Industry trends driving the need for observability

A few big changes in the industry are driving the move toward more Observable warehouses:

E-commerce growth: Faster delivery expectations mean warehouses must be more agile.
Labour shortages: Observable warehouses help optimise limited human resources.
Supply chain volatility: Data visibility enables real-time responsiveness.

According to a 2025 McKinsey report, companies that invested in real-time warehouse visibility were 33% more likely to exceed customer expectations and reduce fulfilment costs.

‍Don’t let lack of visibility hold you back

Warehouses can no longer afford to operate without clarity. The first step toward transformation is simple: see clearly. When you do, every other improvement becomes not just possible, but inevitable. Dexory is already helping warehouses across industries make this critical shift. The journey from blind to observable isn’t just a technology upgrade – it’s a mindset shift toward continuous improvement.

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Using AI-powered insights, Kallikor’s Adaption platform models and simulates complex operational scenarios to enable businesses to adopt new technologies and rehearse the transformation of their supply chains, so they can implement change and optimise their operations with confidence.

Using the Adaption platform, Morrisons is creating a comprehensive digital twin of its end-to-end supply chain, a fully interactive model that mirrors the complexity, scale, and pace of its national network. This transformational capability provides a powerful design space where Morrisons’ teams can experiment, test, and optimise decisions with unprecedented speed and precision, from warehouse operations to network-wide flows. More than a model, it becomes the environment where supply chain reality and strategic intent meet, aligning decisions, testing trade-offs, and unlocking gains in efficiency, resilience, and customer responsiveness.

As the partnership scales, Morrisons will operate with a living digital model fully integrated into its day-to-day operations, enabling continuous optimisation and proactive adaptation to market shifts. This strategic collaboration will position Morrisons at the forefront of supply chain innovation, enabling the delivery of sustained growth, operational excellence, and market-leading customer experiences through faster, smarter, and more agile decision-making across its business.

Ross Eggleton, Group Director: Logistics, Supply Chain & Technology at Morrisons, said: “Partnering with Kallikor will help us make better decisions faster. By using AI to bring the real and synthetic worlds together, we can design and evaluate changes across our entire supply chain. That means we can move quickly, solve the right problems, and ensure that every supply chain decision supports the bigger picture, delivering greater value and availability for customers while improving our efficiency and resilience.”

Jonathan Barrett, Kallikor

Jonathan Barrett (pictured, above), Kallikor CEO, said: “We’re witnessing a fundamental shift in supply chain strategy. Organisations that can redesign their networks dynamically, test multiple scenarios, and make evidence-backed decisions at speed will define tomorrow’s competitive landscape. This partnership positions Morrisons to turn market volatility into a competitive advantage through faster delivery, optimised cost structures, and complete alignment between operational execution and strategic vision.”

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Synopsis:

In this webinar Steven Timberlake of Infios discusses how you can measure your organisation’s level of supply chain maturity and the steps involved in developing greater efficiency and resilience in today’s challenging environment. Together with Peter MacLeod, Steven will explore topics including artificial intelligence, automation and system modernisation and outline how they form part of the practical steps that any organisation can implement today to relentlessly improve supply chain performance tomorrow.

Steven Timberlake, Infios

Steven Timberlake provides thought leadership and strategic challenge around supply chain execution as the Vice President of Sales Northern Europe at Infios. In his role, Steven plays a pivotal role in consulting businesses on transforming their supply chain execution, leveraging his extensive experience to drive strategic initiatives and foster growth opportunities. With over two decades of experience in technology and supply chain, Steven has established himself as a strategic leader adept at driving growth for his customers. His innovative approach to enterprise engagement has enabled organisations to navigate complex challenges and achieve sustainable success in today’s dynamic supply chain environment.

Register to watch it here now

The name Infios draws inspiration from the concept of infinity, representing the vast, interconnected global marketplace and the limitless opportunities to help businesses create their future. Infios is built on the belief that supply chains should be agile, intelligent, and constantly evolving to meet the demands of a changing world. By leveraging advanced technologies, data-driven insights, and a deep understanding of customer needs, Infios delivers innovative solutions that drive efficiency, lower costs, and empower businesses to succeed in an increasingly competitive marketplace.

“Supply chains are the backbone of modern business and global progress. And when they work better — simpler, faster, smarter — businesses thrive, people benefit, and communities become stronger. We believe that the future is better when supply chains work better,” said Ed Auriemma, CEO of Infios. “Our goal at Infios is to work alongside our customers to provide solutions that meet today’s challenges while thinking ahead to solve tomorrow’s problems.”

Infios integrates order management, warehousing and fulfillment and transportation management into a comprehensive suite of solutions, equipping businesses with the tools they need to navigate today’s complex supply chain landscape. Infios is dedicated to its customers, evolving with them to provide scalable, adaptable solutions that meet their changing needs. This flexibility enables customers to optimize every aspect of their operations with versatile, scalable, and future-ready capabilities. With a thoughtful approach to innovation, the company integrates data, predictive analytics, and AI-driven insights to help businesses stay ahead, anticipating challenges and opportunities before they arise.

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In a country of 211 million people, Bem Brasil covers up to 55% of the national demand for products like smiley chips (carinhas) and onion rings, among other specialities. The company also exports to South America, Taiwan, Singapore, the US and Mexico, where it holds a commercial partnership with Walmart.

“Mecalux’s solutions give us complete control over our stored goods. That translates into faster, safer and more cost-effective logistics operations,” says Célio Zero, Operations Manager.

The two Mecalux clad-rack warehouses have provided 66,000 pallet positions. Automation has helped Bem Brasil increase production by 10% and revenue by 30% over the past year. Inside the facilities, kept at -25 °C, the Automated Pallet Shuttle system inserts and retrieves goods autonomously. Conveyors connect the storage and production areas to maintain a continuous flow of raw materials and finished products. This robotic infrastructure eliminates the need for lighting during operations, improving energy efficiency.

Bem Brasil ensures the quality and traceability of its frozen products with Easy WMS, which monitors inbound, putaway and outbound processes in real time. The Mecalux warehouse management system applies the FEFO (first-expired, first-out) method to prioritise the dispatch of products with the nearest expiry date. By optimising inventory turnover, this strategy minimises food waste.

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The partnership, which uses Dexory’s autonomous robot and AI-driven platform, is delivering transformational results across CSG’s Barnsley, South Yorkshire warehouse, which holds a wide range of surplus stock across food, homeware, personal, and pet categories.

Due to the fast-paced nature of surplus redistribution, accurate and timely stock processing is critical. Historically, inaccuracies in stock levels have led to some picking and dispatch delays. By deploying Dexory’s real-time data and automation solution, CSG is now able to track stock with a level of accuracy and speed not previously possible – with an increase of over 300 pallets added to the warehouse management system (WMS) during the trial period alone.

AI-Powered Robotics

“The Dexory solution stood out as the most effective and least disruptive option after reviewing several providers,” said Martin Upton, Operations Director, Company Shop Group. “It’s fast, flexible, and has integrated seamlessly with our existing warehouse management system. The system has also significantly increased visibility into our Dispatch area – something we had limited access to before. This has dramatically increased efficiency and enabled smoother product flow throughout our operation.”

Dexory’s solution is now used not only for stock integrity – ensuring stock is stored in the right location and allowing for rapid issue resolution – but also to support dispatch operations by providing by-date priority lists and real-time views of dispatch pallets. The robot’s ability to perform multiple autonomous scans per day empowers operational teams to act quickly, identify root causes of issues, and implement targeted training and continuous improvement efforts.

“We’re proud to support a mission-led business that is tackling waste reduction across the industry,” said Oana Jinga, Chief Commercial & Product Officer and Co-founder of Dexory. “By combining our AI-powered robotics and real-time data platform, we’re enabling their team to spot issues sooner, react faster, and ultimately deliver a more effective and efficient end-to-end process – turning warehouse visibility into tangible operational and environmental impact.”

Oana Jinga, Dexory

The project has already freed up valuable time for the client’s stock control team, enabling them to focus on wider efficiency initiatives across operations. With the proven benefits in inventory control and process flow, Company Shop Group sees this partnership as a key pillar in achieving its long-term goal: creating a world where no surplus product goes to waste.

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“Tariffs and trade shocks have put UK firms under real pressure – but they’re not retreating, they’re rewiring. This is a strategic reset – not just a stopgap. The UK is leading Europe in nearshoring and local sourcing, not just to cut costs but to take control. This is a strategic reset – not just a stopgap,” says Matthew Woodcock, Regional VP, CVM/Supply Chain Strategy (EMEA & APAC), Coupa.

Businesses are responding to rising global tariffs and supply chain volatility by taking decisive action. According to new research from Coupa, a leading AI-native total spend management platform, 85% of UK companies are increasing or planning to increase nearshoring over the next 12 months to shift operations closer to home – more than any other country surveyed, including the US (74%), Germany (74%), and France (66%).

Rather than absorb cost shocks passively, UK businesses are strategically reshaping their supply chains to prioritise local suppliers, reduce dependencies on high-risk regions, and build greater resilience into business operations.

Pricing remains a primary pressure point. 61% of UK suppliers plan to raise prices by five to ten percent – the highest share across any country surveyed – with a further 22% expecting to increase prices by more than ten percent. These hikes are expected to hit consumers directly in the coming months, with rising supplier costs likely to be passed along the value chain. To manage margin erosion, businesses are turning to mitigation strategies such as stockpiling inventory (38%) and increasing local sourcing (37%), signalling an urgent shift to contain upstream costs and safeguard downstream stability.

While almost half (49%) of UK firms report that recent US trade policies have negatively impacted their bottom line, only six percent forecast revenue losses above ten percent. This suggests businesses are feeling the pressure but remain comparatively confident in their ability to adapt.

This resilience is underpinned by decisive sourcing shifts. UK companies are moving away from perceived high-risk regions, with 31 percent pulling back from the US and 27 percent from China. Instead, they are increasingly prioritising domestic and European partners, with 41 percent sourcing more from the UK itself, 41 percent from Germany, and 31 percent from France. In total, 75 percent of UK suppliers now prioritise local sourcing in their future strategies – a higher proportion than in Germany (70%) or France (67%).

At the same time, the criteria UK buyers use to select suppliers is shifting. While price remains important, businesses are placing greater emphasis on reliability and compliance. 53% of UK buyers cite proven quality and reliability as a top priority. Stable and competitive pricing (57%) and full regulatory compliance (47%) is also important. These figures point to a clear pivot from cost-efficiency to risk reduction and supply assurance.

Woodcock adds: “Periods of disruption always create space for reinvention – and the smartest companies are using this moment to sharpen their competitive edge. UK firms aren’t just surviving – they’re simplifying, localising, and building supply chains fit for the future.”

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“ASOS is a prime example of how leading retailers can use Process Intelligence to transform their operations,” said Rupal Karia, General Manager for UKI and MEA at Celonis. “With Celonis, ASOS gets unprecedented visibility into its end-to-end supply chain and can identify and act upon opportunities for improvement in real-time. Together, we’re unlocking the full potential of ASOS’ supply chain to deliver faster, smarter, and more efficient operations at scale.”

Transforming ASOS’ Supply Chain and Driving “Speed to Customer” with a Process-first  Approach

As a leading online fashion retailer, ASOS operates in a highly dynamic and competitive market where speed to customer is a critical differentiator. Leveraging the Celonis Process Intelligence platform and its game-changing object-centric process mining (OCPM) technology, ASOS can connect its product, inbound supply chain, logistics and outbound delivery & returns teams, providing a holistic, real-time view of the full supply chain process—from purchase order to putaway to products on the doorstep. This enables ASOS to gain actionable insights into key supply chain performance metrics, which will help drive faster, more reliable order fulfillment​.

“With Celonis, we’ve connected our entire supply chain—from intake and inbound to outbound and returns—enabling teams to break down silos, streamline processes, cut costs, and deliver the latest trends to customers faster,” said Laurence Moore, Head of Strategic Projects, Supply Chain at ASOS.

A Vision for the Future: Scaling Process Intelligence across ASOS

As part of its long-term digital transformation strategy, ASOS is exploring ways to expand Celonis across multiple business functions, including Purchase-to-Pay, Order Management, IT Service Management, and Warehouse Management​. With real-time process monitoring, ASOS can further enhance efficiency, reduce costs, and continue delivering an outstanding customer experience.

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The scalable solution will be implemented in two different phases to ensure business continuity throughout the transformation. Geek+’s P800 V6.0 solution – for pallets and shelves movement – significantly enhances picking efficiency, inventory accuracy, and space utilisation — key advantages for third-party logistics providers facing growing customer demands.

“This project demonstrates the power of flexible automation,” said Simon Houghton, Sales Director UKI at Geek+ . “Our Shelf-to-Person system enables scalable growth without disruption. We’re proud to support Yusen Logistics in their first of this kind automation project in the UK but also in the Europe region”

For Yusen Logistics, the deployment aligns with a broader digitalisation strategy aimed at increasing efficiency and responsiveness across its operations.

“By integrating Geek+’s robots, we will be able to improve accuracy, agility, and throughput,” said Ben Bird, Business Development and Solutions Design Director at Yusen Logistics. “The system will give us the flexibility to scale alongside our customers’ evolving needs while gaining a great customer experience”.

The implementation will be delivered as part of a wider warehouse automation project led by Logistex, ensuring seamless integration with Yusen’s infrastructure and business processes.

“It’s a pleasure working with Yusen and Geek+ on such a forward-thinking project,” said Justin Saw, Business Development Director at Logistex. “Together, we look forward to delivering a future-ready solution with immediate results.”

The project highlights how Goods-to-Person robotics are reshaping the logistics landscape, offering 3PLs fast ROI, reduced labour reliance, and high safety standard. With this deployment, Yusen Logistics is well-positioned to lead in a rapidly changing market.

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By analysing its own first-party customer service data, and highlighting commonalities and categories from 30,000+ tickets, over the last 12 months, the team was able to draw insights on how omnichannel brands can measure fulfilment and logistics performance via its customer service requirements.

Lee Thompson, CEO at fulfilmentcrowd, added: “eCommerce retailers should seek to implement global fulfilment that leverages technology for better visibility. Trusted by 250+ omnichannel brands, our platform is the backbone for resolving and preventing customer service pain points, empowering brands to scale, grow, and expand globally”.

Lee Thompson, FulfilmentCrowd

Unveiling some year-over-year trends in service-related fulfilment issues as the eCommerce landscape has grown, Chelsea Banister, Head of Customer Operations at fulfilmentcrowd, added: “Our data shows that the majority of conversations (78%) that we have with clients relate to order queries or issues. Other common categories raised included custom orders (9%), inventory transfers (4%), products (3%), and returns (2%). Conversations related to rework and task requests, charges and billing, setup and configuration, and API and integration made up less than 5% of conversations combined.

fulfilmentcrowd’s Chelsea Banister

“The data also revealed that, generally, ticket volume peaks in Q4 (October to December), likely reflecting peak eCommerce season challenges. Throughout the year, we tend to have the most customer service conversations with our Health and Beauty partners – in this sector, we are having regular conversations around how to best manage batch control for items that expire. Other common themes in our recent customer service conversations across all sectors include aspects related to US tariffs, our B2B capabilities, and AI.”

When issues arise, the team also suggests using data analytics to pinpoint recurring issues, consistently review your supply chain for weak spots, and conduct a post-mortem meeting with your team to discuss lessons learned.

Technology can also play a key role in this – Austin Waddecar, Chief Product Officer at fulfilmentcrowd, added: “In many cases, fulfilment chaos is the result of poor visibility. If you don’t know where your stock is or what stage an order is at, how can you fix a problem? Technology is your best friend here. Use it to your advantage. Investing in the right technology can save you time, money, and a whole lot of customer complaints – and that’s where we come in.

“A few examples of our tech solutions include real-time tracking, inventory management software, and shipping rules automation. With real-time tracking, you’ll also notice a huge decrease in customer service enquiries in terms of WISMO (where is my order) / WISMR (where is my return) if you offer a self-service solution. Your team will then have more time to spend on those complex issues that don’t always have an immediate fix.

“Inventory management software can help to reduce stockouts and overselling with better forecasting tools, and shipping rules automation can optimise your shipping rules to avoid delays and errors.”

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