The Challenge: Inefficiency and Lack of Visibility

Shorr Packaging, a leading distributor of packaging solutions, faced significant logistical hurdles in managing its deliveries across the U.S. With thousands of shipments departing from seven facilities, the company struggled with:

• Manual delivery routing – Every truck’s route was planned by hand, consuming valuable time.
• No real-time visibility – Once trucks were on the road, there was no way to track their status or progress.
• Lack of proof of delivery – Customer service had no quick way to verify completed deliveries, leading to inefficiencies.

Each facility managed logistics differently—some relied on spreadsheets, others on paper, and some just “figured it out” daily. On average, two hours per day were wasted manually planning routes.

The Solution: Going Digital

Recognizing the need for an overhaul, Shorr’s logistics leaders partnered with Levata, parent company of Barcodes, Inc., and Descartes to implement a fully digital routing and delivery management solution.

• Automated Routing – Descartes’ advanced software replaced manual planning, optimizing routes in real time.
• Full Visibility – Every truck, driver, and delivery became trackable in a single solution.
• Proof of Delivery – Zebra mobile devices allowed drivers to capture photos, signatures, and real-time updates.

To ensure seamless execution, Levata also helped integrate a smart cellular management solution. This ensured Shorr’s delivery team stayed connected across different locations without service interruptions.

The Results: A Game Changer for Efficiency

The impact of digital transformation was immediate and powerful:

• 87% reduction in routing time – What used to take two hours per day now takes just 10-15 minutes.
• Fewer routes, fewer miles – Deliveries that previously required 12 drivers now take only six or seven.
• Faster customer service – Real-time proof of delivery eliminated back-and-forth calls.

As Nick Matuck, Senior Director of Global Logistics, put it:

“We went from zero to 100% visibility overnight. Productivity increased, costs went down, and our teams now have real-time insight into our entire delivery network.”

Seamless Adoption & Driver-Friendly Tech

While digital transitions can sometimes be challenging, Shorr’s rollout was smooth. The Zebra handheld devices made the system easy for drivers to use, and the step-by-step training ensured everyone adapted quickly.

“I’ve only received positive feedback,” said Ashley Astley, Corporate Logistics Manager. “Drivers love how simple it is, and customer service is thrilled with the proof of delivery feature.”

Final Thoughts: Digital Tools, Real-World Impact

By adopting digital routing and proof of delivery technology, Shorr significantly improved its logistics operations—reducing costs, increasing efficiency, and enhancing the customer experience.

For businesses aiming to optimize delivery management, Shorr’s success story highlights how the right technology can drive meaningful operational improvements.

Contact us to learn more. 

In the past decade, automation has transformed the way warehouses operate. From conveyor systems to robotic picking arms, automation technologies have brought new levels of efficiency to supply chains. But as impressive as fully automated systems can be, the most successful warehouses today aren’t eliminating the human worker—they’re empowering them.

Welcome to the era of hybrid automation—where smart technology and skilled people work side by side to boost productivity, agility, and morale from day one. Read on to learn how technology leaders like Newcastle Systems enhance warehouse operations by engineering solutions that exponentiate real worker potential.

What Is Hybrid Automation?

Hybrid automation combines automation tools and systems with human labor, allowing each to do what they do best. The technology side excels at speed and accuracy, while people bring flexibility, critical thinking, and problem-solving skills that technology can’t replicate.

This model isn’t just a compromise between man and machine—it’s a powerful synergy. According to Newcastle Systems’ 2023 Industry Report on Automation in Warehousing, “Warehouses that leverage automation to support—not replace—their workforce see higher productivity gains and improved employee satisfaction.”

Why It’s Not About Replacing People

While it’s tempting to chase the dream of a fully automated, human-free warehouse, the reality is more nuanced. Technology can’t replicate the adaptability, judgment, and decision-making abilities of a well-trained team. In fact, 81% of warehouse operators surveyed by Newcastle Systems agreed that keeping the human element in operations is crucial to maintaining flexibility and customer satisfaction.

Rather than viewing automation as a replacement for workers, leading operations are now using it to enhance human potential.

Mobile Powered Workstations: A Smarter Path to Productivity

A perfect example of hybrid automation in action is the use of Newcastle Systems’ mobile powered workstations. These units allow workers to bring power and computing directly to the point of task, eliminating the need to walk back and forth to a fixed workstation.

The results? Doubling productivity—without doubling the cost.

Unlike complex robotic systems that require heavy infrastructure, lengthy implementation, and big budgets, mobile powered carts are affordable, flexible, and scalable. They instantly boost efficiency by reducing wasted movement and downtime, and they support employees instead of replacing them.

As the Newcastle report highlights, “Technologies that enhance workers’ effectiveness are more readily adopted and create less friction within the workforce.”

Empowered Workers Are Happier Workers

Hybrid automation doesn’t just improve operations—it also improves job satisfaction. By removing tedious tasks and minimizing unnecessary travel, tools like mobile workstations help workers feel more in control and more valued.

The Newcastle study found that employees using powered carts reported higher job confidence and satisfaction. Workers using the Newcastle Mobile Workstations felt empowered with tools that make their jobs easier—not harder—making them more likely to stay engaged and less likely to leave their current employer.

The Bottom Line: Humans + Automation = Better Warehouses

The future of warehousing isn’t one where robots take over—it’s one where people are equipped to do their best work with the help of smart automation.

Mobile powered workstations are a standout example of hybrid automation done right: low cost, easy to implement, and impactful from day one. They deliver the best of both worlds by boosting productivity while keeping the human touch that warehouses still need to thrive.

If you’re looking for a way to modernize your operations without sacrificing flexibility or your workforce’s well-being, hybrid automation is the answer—and Newcastle Systems is leading the way.

Explore the full report: How Automation Is Transforming the Modern Warehouse – Newcastle Systems Industry Report

Contact Barcodes Inc. today to learn more about mobile workstations and other warehouse automation solutions for your operations.

Premium Guard Inc. (PGI) is a leading global manufacturer of aftermarket automotive products, including filters and wiper blades. Since its founding in 1996, PGI has focused on designing, manufacturing, and distributing high-quality products for automotive, diesel, power-sports, and specialty filter markets. Offering complete turnkey private label programs to retailers, buying groups, and independent warehouse distributors, PGI faced operational challenges in supply chain accuracy and efficiency. To address these challenges, PGI partnered with Levata, parent company to Barcode’s Inc., to implement a cutting-edge RFID-based inventory tracking and shipment accuracy system.

Business Challenge

Premium Guard’s supply chain is complex, with a high expectation of accuracy from auto parts retailers, distributors and aftermarket businesses. Ensuring the right part and the right quantity shipped to the correct destination on time are critical, as delays or errors can result in customer dissatisfaction and costly chargebacks.

“We ship high volumes weekly to multiple automotive aftermarket retailers, often filling entire truckloads with each order. Manually double-checking and auditing every pallet is overwhelming, yet missing products can lead to costly chargeback fees. After discovering the capabilities of RFID technology, we partnered with Levata to implement a smarter solution—enhancing visibility, improving accuracy, and elevating customer service,” said Jim Allosso, Director of Warehouse Operations at Premium Guard.

Key challenges included:

• Mis-shipments leading to chargebacks and return freight payments.
• Inventory discrepancies impacting operational efficiency.
• Lack of real-time visibility in warehouse operations.

Recognizing the need for improvement, PGI’s leadership committed to a solution that would ensure customers received exactly what they ordered, leading to the adoption of an RFID-based workflow.

The Solution

Premium Guard needed a partner that could provide customized, cutting-edge technology that addressed key challenges in supply chain management. Levata’s RFID systems, such as RFID tunnels, dock doors, and mobile readers, offer accurate inventory tracking and real-time visibility, which are critical for reducing mis-shipments, lowering chargeback costs, and improving operational efficiency.

With Levata, PGI has launched a phased RFID implementation. PGI sought to enhance customer service through enhanced inventory management operations for its largest customer, a leading national retailer of automotive parts and accessories. The solution involved multiple components tailored to PGI’s unique operational needs. PGI committed to an extensive relabeling project to fully integrate RFID technology effectively, involving the relabeling of over 600,000 boxes. Additionally, ten vendors began incorporating RFID labels into their shipments, further streamlining PGI’s receiving process.

RFID Infrastructure & Technology
A custom-built RFID Tunnel (SLS T-Series) was integrated with PGI’s ERP system to count pallet content accurately and validating that shipments include the right materials. RFID Dock Doors (SLS D-Series) were installed to ensure shipments were loaded onto the correct trucks, while RFID Mobile Readers (SLS M-Series) supported cycle counting of pallets in the warehouse. To provide real-time tracking and data insights, PGI leveraged the SLS View RFID cloud software.

To further streamline operations, PGI deployed powered mobile carts powered mobile carts equipped with RFID label printers and AirTrack Performance label supplies, allowing for efficient RFID labeling right on the warehouse floor. Additionally, handheld mobile RFID readers and mobile computers enabled mobile scanning and verification, creating seamless interaction with the RFID system powered by cloud-based software.

“From day one, we’ve worked with a dedicated Levata team deeply involved in every phase of our project,” said Jim. “Their solution architects designed a highly customized system, field experts collaborated directly with our floor teams, and specialists guided our manufacturing partners through new processes. No matter the challenge, Levata has been there with reliable support we can count on.”

Benefits and Results

Premium Guard has already seen significant improvements with the new system:

• Highly accurate scanning, with both the RFID tunnel and dock doors performing exceptionally well.
• Enhanced insights from customized reporting.
• Stronger supply chain visibility, reducing inefficiencies and ensuring greater accuracy in shipments.

With the success of the initial phase, PGI is planning to expand their RFID implementation. It will roll out the new process for other large customers, resulting in a dedicated dock door for each customer for smooth, efficient order verification. The expansion will include more vendor participation, too. Having vendors ship parts with RFID labels enables seamless integration with the warehouse’s RFID system, improving inventory accuracy, accelerating processing times, and enhancing overall supply chain efficiency.  

By leveraging Levata’s advanced RFID solutions, PGI has significantly improved its supply chain efficiency, reduced operational costs, and strengthened its reputation as a reliable partner in the automotive aftermarket industry. To learn more about our RFID technology solutions, contact us today!