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

Introduction

Yusen Logistics, a global supply chain solutions provider, faced a specific visibility challenge at its Wellingborough site, where high-value goods such as TVs were stored in palletised block stacks - an efficient use of space but a significant challenge for stock accuracy. With no barcodes visible and stacks several units deep, teams relied on time-consuming manual counts, creating risk across a fast-moving, high-value inventory environment.

“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

The challenge

Block-stacked storage at the Wellingborough site meant teams had no reliable way to validate inventory without manual counts, leading to reduced stock accuracy, delayed replenishment, manual investigations and risk of errors in outbound preparation. With high-value consumer electronics moving quickly through the warehouse, a faster, safer and more scalable approach to maintaining accurate records was essential.

The solution

Dexory developed and deployed its Block Stack feature on the autonomous robot, using advanced LiDAR scanning to build a 3D digital twin of deep storage locations without moving a single pallet. The robot scans and models stacked pallets, matches real-world dimensions and counts with WMS data, and flags discrepancies in real time. Covering both racking and block stack zones, the robot scans up to 10,000 pallet locations per day in racking and all block-stacked units in under 30 minutes - without disrupting operations.