How Pick count helped Maersk and iB Cargo improve pick accuracy and dramatically reduce manual counting effort

The Maersk and iB Cargo operation is a large, high-volume warehouse dedicated to serving one of the largest global furniture and interior decoration companies. The site supports more than 107,000 pallet positions across inbound, outbound, transit and bulk storage areas.

Within the operation, pick face locations play a critical role. Each product is allocated a dedicated pick face, and any discrepancy at this level has an immediate impact on picking speed, replenishment decisions and outbound service levels.

The challenge

Before deploying Dexory’s Pick Count feature, pick face accuracy was managed through a structured, manual cycle counting process within the WMS. This approach ensured a high level of control and reflected the site’s strong focus on inventory quality and compliance.

However, as the operation scaled in size and throughput, this method became increasingly resource-intensive. On a weekly basis, all pick face locations were physically counted, even though the majority were already accurate. As an example, reviewing close to 2,000 locations required between 16 and 20 hours of work to produce an initial view of discrepancies, and involved multiple roles, including on-floor quality checks and secondary validation in line with four-eyes principles.

While effective from a control perspective, manual counting also made it harder to prioritise attention. Some discrepancies flagged by the WMS were linked to counting variability rather than true stock issues, which added noise to the process and slowed down corrective actions where they were genuinely needed.

The team had a robust process in place, but needed a way to focus effort on the small number of locations that truly required intervention, without repeatedly checking those that were already correct.

The solution

Maersk and iB Cargo introduced Dexory’s Pick Count feature to automate inventory visibility and focus human effort where it adds the most value.

Using Dexory’s autonomous robots, the entire pick face area is scanned weekly. The resulting data is analysed to clearly separate locations with no discrepancy, minor discrepancies, and significant discrepancies that require physical verification.

Rather than physically counting every pick face location, the team now concentrates only on discrepancies above an agreed threshold. This shift fundamentally changed how inventory control is managed at the site.

The operation moved from “checking everything” to “checking only what really matters”.

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The results

A step change in cycle counting efficiency

The most immediate impact was a dramatic reduction in manual counting time. With Pick Count in place, only locations with significant discrepancies are physically verified.

In practice, this means that out of more than 200 flagged locations, only around 10 typically require adjustment. What once took up to 20 hours of manual work now takes one to two hours at most.

Higher pick face accuracy and operational confidence

Pick Count also increased confidence in inventory accuracy. Around 70% of pick face locations show no discrepancy at all, indicating that stock is correctly placed and maintained. Minor discrepancies are understood and tracked, often linked to nested or atypical articles, while significant discrepancies are resolved before operations begin.

Faster picking and better replenishment decisions

Improved pick face accuracy had a direct impact on picking speed and outbound performance. With reliable inventory data, pickers are far less likely to encounter empty or underfilled locations, reducing interruptions and waiting time.

Pick Count reads partial quantities on the pallet, ensuring replenishment decisions are made at the right time.

As a result, picking flows more smoothly and replenishment becomes proactive rather than reactive.

Better use of people and equipment

Fewer people are involved in routine checks, reach trucks are no longer tied up for counting activities, and quality teams can focus on exceptions rather than repetitive tasks.

This shift allows the team to spend more time on value-adding activities while maintaining a higher level of inventory accuracy than before.

Improved warehouse hygiene and discipline

An additional benefit of Pick Count was improved warehouse hygiene. To ensure high-quality scanning results, the team introduced regular clean-up routines, improved label readability, reduced obstructions at aisle entrances, and reorganised pick face layouts.

These changes not only improved scan quality but also contributed to a safer, more organised warehouse environment.

A stronger relationship with the end customer

Accurate pick face inventory, faster investigations and visual proof through photos have strengthened trust with the end customer. Claims and questions can now be resolved more quickly, with clear evidence to support decisions.

Conclusion

For Maersk and iB Cargo, Pick Count augmented the team. By removing unnecessary manual work and focusing attention on real discrepancies, the operation achieved higher accuracy, faster picking, and better use of resources.

The result is a more predictable, data-driven warehouse operation that supports both operational excellence and long-term customer relationships.