Case studies

Real-time warehouse intelligence transforms inventory accuracy and production efficiency for global automotive manufacturing business

June 3, 2025

The challenge

In a high-pressure production environment, where timing and accuracy are critical, even small inefficiencies in warehouse operations can snowball into significant business disruptions. This was the case for a global manufacturing business operating a small lot warehouse with high bay racking.

The company experienced a range of persistent issues tied to inventory integrity, which had direct consequences for both production continuity and manpower efficiency. They had also trialled drone technologies in an effort to automate inventory checks. However, these systems fell short:

Frequent production stoppages due to delays in locating critical materials or errors in stock availability, resulting in material financial losses.
Manpower inefficiencies, including excessive time spent on manual inventory reconciliation, and global book-out procedures that drained operational resources.
Non-standard workarounds became common, eroding overall productivity and increasing the risk of errors.

Without clear, real-time visibility into the state of inventory - especially in upper rack levels - decision-making was delayed, and performance across the warehouse floor was compromised.

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The solution

To address these challenges, the company implemented DexoryView, the AI-powered warehouse intelligence platform from Dexory. Combining advanced robotics with real-time data analysis, DexoryView offers a transformative solution for managing complex inventory environments.

At the heart of the solution are autonomous mobile robots, which continuously scan and map the warehouse, capturing granular data across every storage location - regardless of visibility or height. That data is instantly fed into DexoryView’s platform, generating a real-time digital twin of the warehouse, accessible to operators, planners, and leadership.

This enabled:

Automated daily inventory scanning: replacing manual counts and reducing the need for disruptive, resource-heavy global book-outs.
High-bay rack tracking: with consistent and accurate data capture even in areas traditionally difficult to audit manually.
Proactive verification: of WMS records, enabling the team to detect discrepancies early and avoid costly errors or stockouts.

“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

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The benefits of the solution

The deployment of DexoryView has led to significant operational improvements and measurable business benefits:

Improved visibility: DexoryView enables accurate, consistent tracking of materials - especially in high-bay racking - even when items were not correctly recorded in the warehouse management system (WMS).
Automated daily audits: Instead of relying on periodic manual checks, the warehouse now performs daily inventory scans automatically. This has reduced downtime, eliminated reliance on global book-outs, and freed up skilled personnel for more value-added work.
Accurate space and location tracking: The robots identify empty storage locations and analyse space utilisation, improving trailer unloading efficiency and optimising storage layouts.
High-level verification without risk: By scanning the upper racks autonomously, the solution has removed the need for double-handling or elevated manual interventions, improving both speed and safety.
Smarter replenishment and stock accuracy: DexoryView verifies storage records in real time, helping the team anticipate and prevent stockouts or unnecessary expedites, improving planning accuracy and cost control.
Obsolescence monitoring: With continuous inventory monitoring, the system flags outdated or at-risk materials, helping the business reduce excess and obsolete (E&O) waste - a key contributor to bottom-line efficiency.

“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

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Conclusion

Implementing DexoryView has been a turning point in warehouse operations. By automating daily audits, unlocking high-bay visibility, and transforming data into actionable intelligence, the company has significantly reduced operational waste, improved production uptime, and enhanced its ability to respond to real-time supply chain needs.

With efficiency gains, safer operations, and better control over inventory health, the business is now better positioned to drive commercial success - backed by the intelligent automation and data precision of Dexory.

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Want to see how Dexory can transform your warehouse operations?

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