Case studies

Ziegler slashes downtime and drives operational excellence with DexoryView

June 3, 2025

The challenge

As a global logistics leader operating in high-throughput environments, Ziegler faced growing pressure to maintain visibility, accuracy, and efficiency across its expansive warehouse operations. One of its key UK facilities - with over 55,000 pallet locations and a complex layout - presented several core challenges:

Lack of real-time visibility:
With vast stock volumes and tight delivery deadlines, Ziegler needed more granular, real-time insights into its inventory to reduce downtime and eliminate stock anomalies.
Manual stock counting and error investigation:
Routine stock takes were labour-intensive, taking days to complete and disrupting operations. Even small scan inaccuracies could cascade into major customer service issues, requiring weeks of manual investigation and correction.
Recurring operational errors:
Problems such as mispicks, misplaced inventory, and incorrectly labelled pallets occurred too frequently - and often went undetected until they caused delays or fulfillment issues.
Previous technology trials fell short:

Ziegler explored advanced options, including drone-based systems and automated shuttle racking, but found these solutions were either limited in coverage, lacked real-time accuracy, or required intrusive infrastructure changes. None fully solved the challenge of continuous, high-fidelity visibility across a large and dynamic warehouse environment..

“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

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The solution

To address these challenges, Ziegler implemented DexoryView, a cutting-edge warehouse data intelligence platform from Dexory. Powered by autonomous robotics and a digital twin interface, DexoryView gave Ziegler the ability to monitor and manage its warehouse environment in real time.

Autonomous data capture:
Dexory’s robots scan the full warehouse environment autonomously and continuously, collecting real-time data on inventory locations, stock levels, and potential errors.
AI-driven digital twin platform:
DexoryView creates a dynamic, visual replica of Ziegler’s warehouse, offering instant visibility and pinpointing discrepancies like mispicks or misplaced pallets before they disrupt operations.
Proactive error detection and root cause analysis:
By identifying trends in recurring errors, Ziegler can now target and resolve the root causes of inefficiencies - streamlining its processes and reducing downtime.
Immediate and ongoing impact:
Within just one month of implementation, Ziegler began seeing significant improvements in stock accuracy, process enforcement, and overall operational performance.

The benefits of the solution

After evaluating multiple approaches, Ziegler selected DexoryView, a robotics-powered real-time data intelligence platform from Dexory. DexoryView provided a scalable, reliable solution capable of operating seamlessly within the warehouse’s existing infrastructure. The deployment of DexoryView has delivered rapid and measurable value for Ziegler’s UK operations:

Faster stock recovery and fewer errors:
The team is now able to quickly locate missing pallets, detect mispicks early, and address labelling or placement errors in real time - without halting operations.
End of costly shutdowns for stock takes:
Where full stock takes once required four days and weekend shifts, inventory is now continuously monitored - eliminating the need for disruptive audits and manual reconciliations.
Shift to data-driven decision making:
With real-time, visual insights from DexoryView, Ziegler has replaced guesswork with precision. Operations are more agile, issues are resolved faster, and staff are empowered with the data they need to act decisively.
Cultural transformation in inventory control:
The enhanced visibility and insight are driving a broader shift in how Ziegler approaches warehouse management - prioritising proactive accuracy and continuous improvement.
Future expansion and innovation:
Building on early success, Ziegler plans to explore DexoryView’s warehouse layout optimisation features and offer customers live access to inventory data. Additional deployments at other sites are under consideration following ROI review.

“We are working together with Ziegler to replace guesswork with insight… helping the business become more efficient,”
- Oana Jinga, Chief Commercial and Product Officer, Dexory

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Conclusion

Ziegler’s adoption of DexoryView marks a pivotal step in its digital transformation journey. By tackling recurring issues in real time and improving stock accuracy through automation and AI, Ziegler has unlocked new levels of efficiency, reliability, and customer satisfaction. As it looks to expand the solution across more sites, Ziegler is setting a new benchmark for data-driven logistics excellence.

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Want to see how Dexory can transform your warehouse operations?

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