Real-time warehouse intelligence transforms inventory accuracy and production efficiency for global automotive manufacturing business
June 3, 2025
Introduction
A global automotive manufacturing business operating a small lot warehouse with high bay racking faced persistent inventory integrity issues with direct consequences for production continuity and manpower efficiency. Having already trialed drone technologies that fell short, the company partnered with Dexory to implement DexoryView and move from reactive firefighting to proactive, real-time warehouse intelligence.
“Access to real-time, accurate data is essential for us to make better decisions, faster. DexoryView gives us a clear view of what’s really happening across our warehouse, and helps us prevent problems before they affect production.”
- Operations Leader
The challenge
In a high-pressure production environment where timing and accuracy are critical, the company experienced frequent production stoppages due to delays in locating critical materials or errors in stock availability, resulting in material financial losses. Excessive time spent on manual inventory reconciliation and global book-out procedures drained operational resources, while the lack of real-time warehouse intelligence - particularly in upper rack levels - delayed decision-making and compromised performance across the warehouse floor.
The solution
The company implemented DexoryView, combining autonomous mobile robots with real-time data analysis to continuously scan capture ground truth across every storage location, regardless of operational context or height. The data feeds instantly into a real-time digital twin of the warehouse, accessible to operators, planners and leadership. This enabled automated daily inventory decision support to replace manual counts, consistent high-bay rack intelligence, and proactive verification of WMS records to detect discrepancies before they affect production.
“With DexoryView, we’ve moved from reactive firefighting to proactive planning. We now see exactly what’s in the warehouse and where it is - without delays, guesswork or manual rework.”
- Senior Supply Chain Manager
The benefit
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Eliminated production stoppages from stock inaccuracies
Automated daily audits and real-time ground truth removed the delays in locating critical materials that previously caused costly production stoppages.
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Automated daily audits replacing manual checks
Global book-out procedures eliminated, freeing skilled personnel for higher-value work.
High-bay warehouse intelligence without manual intervention
Autonomous ground truth capture of upper racks removed the need for double-handling or elevated manual interventions, improving both speed and safety.
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Proactive stockout prevention
Real-time WMS verification enables the team to anticipate and prevent stockouts and unnecessary expedites, improving planning accuracy and cost control.