Ziegler slashes downtime and drives operational excellence with DexoryView

Introduction

Ziegler, a global logistics leader operating in high-throughput environments, faced growing pressure to maintain visibility, accuracy and efficiency across its expansive warehouse operations. At one of its key UK facilities - with over 55,000 pallet locations and a complex layout - previous technology trials including drones and automated shuttle racking had all fallen short. Ziegler partnered with Dexory to implement DexoryView and replace guesswork with real-time warehouse intelligence.

“Even a 1% miss-scan rate could create major issues, from stock rotation delays to customer service impacts,”
- Ignas Saknaitis, Divisional General Manager for Logistics, Ziegler

The challenge

With vast stock volumes and tight delivery deadlines, Ziegler lacked the granular, real-time operational context needed to reduce downtime and eliminate stock anomalies. Routine stock takes were labour-intensive, taking days to complete and disrupting operations, while even small scan inaccuracies could cascade into major customer service issues requiring weeks of manual investigation. Recurring problems such as mispicks, misplaced inventory and incorrectly labelled pallets frequently went undetected until they caused delays or fulfilment issues.

The solution

Ziegler implemented DexoryView, powered by autonomous robots that scan the full warehouse environment continuously, collecting real-time data on inventory locations, stock levels and potential errors. The AI-driven digital twin creates a dynamic visual replica of the warehouse, pinpointing discrepancies like mispicks or misplaced pallets before they disrupt operations. By identifying trends in recurring errors, Ziegler can now target and resolve root causes of inefficiencies - with significant improvements in stock accuracy and operational performance visible within just one month of implementation.