Yusen Logistics unlocks daily accuracy in block-stacked storage with Dexory

About Yusen Logistics

Yusen Logistics is a global supply chain solutions provider, delivering excellence across contract logistics, freight forwarding, and supply chain management. Their UK operations include high-density storage and complex inventory environments for leading consumer electronics brands.

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The challenge

Limited visibility in block-stacked storage.

At Yusen Logistics’ Wellingborough site, high-value goods such as TVs were stored in palletised block stacks, an efficient use of space, but a challenge for stock visibility. With no barcodes in sight and stacks several units deep, teams needed to rely on time-consuming manual counts to validate inventory, which often meant:

• Reduced stock accuracy
• Delayed replenishment
• Manual investigations and guesswork
• Risk of errors in outbound preparation
  
  

They needed a faster, safer, and more scalable way to maintain accurate records, especially as stock moved quickly through the warehouse.

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The solution: Dexory's Block Stack feature

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Dexory added the Block Stack feature to the autonomous robot, a feature designed to digitise deep storage locations without disruption.

Using advanced LiDAR scanning and a digital twin of the block stack area, the robot:

1. Scans the space and builds a 3D model of the stacked pallets.
2. Matches real-world dimensions and counts with WMS data.
3. Flags discrepancies in real time, such as missing, miscounted, or incorrectly placed items.

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The robot seamlessly covers both racking and block stack zones, scanning up to 10,000 pallet locations per day in racking, and all block-stacked units in under 30 minutes, without moving a single pallet

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The results

97–98% accuracy in daily counts.

With Dexory in place, Yusen Logistics achieved:

• Near-perfect accuracy in block-stacked inventory
• Real-time, reliable stock insights for better planning
• Faster, safer operations, no climbing or manual scanning
• Full visibility for the client’s high-velocity products
  
  

“It's been a pleasure for our team at Yusen Logistics UK, collaborating with Dexory, for one of our key customers! Thank you so much for developing your product with us to overcome the challenges of using Dexory on block stack locations, a great addition to the already brilliant features.”

– Benjamin Bird, Business Development & Solutions Director at Yusen Logistics UK

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Want to eliminate blind spots in your block stacked storage?

Get in touch to see how Dexory can help.

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