Pick Path and Wave Optimization

DHL Supply Chain, the global logistics division of Deutsche Post DHL Group, has deployed AI-driven optimization across multiple warehouse formats. In one documented implementation, DHL used a simulation-based optimization tool called IDEA to improve cluster picking in medium-size warehouses, reducing heavy aisle congestion (four or more carts in one aisle) from 28% of the time to 18% while reducing the number of pickers needed to maintain throughput. In a separate warehouse layout optimization project for a European footwear retailer, DHL partnered with analytics firm Logio and achieved a 22% reduction in picker walking distance and an estimated 8% increase in picking productivity through data-driven slotting and layout redesign. DHL has reported overall results including up to 50% reduction in warehouse employee travel distance and 30% productivity increases in order picking across facilities using AI-driven routing and resource allocation.

In the manufacturing and distribution sector, Southwire, a leading North American wire and cable manufacturer supplying major retail chains, implemented the Lucas Systems Dynamic Work Optimization solution to supplement the company's warehouse management system. The deployment achieved a 30% to 50% increase in e-commerce picking productivity, a 90% reduction in training time for new pickers, and a twofold increase in lines picked per hour, according to Lucas Systems. A separate pet supply retailer using the same platform reported a 33% increase in throughput. These results were achieved without changes to warehouse layout or the addition of robotics, relying solely on AI-based batching and path optimization layered on top of existing infrastructure.