Throughput Doubled with Warehouse Management

A growing consumer products company has scaled operations without added labour, achieving 98.5% accuracy and zero audit errors. Durham Brands (DBA Gimme Beauty®), a hair accessory company, has transformed its warehouse operations with Infios Warehouse Management (WM) – enabling the company to improve accuracy and deliver record-breaking peak season performance.

Following the implementation of Infios WM, Durham Brands exceeded its December peak forecast by 170% while nearly doubling throughput from 10,000 to 19,000 cases per FTE, without adding labour. The company also achieved 98.5% inventory accuracy and recorded zero audit errors for the first time ever.

“This strategic move was more than a system upgrade, it was a meaningful shift in how we operate. We scaled through our biggest volume surge in company history without adding labour, and we improved accuracy and created opportunities to promote from within. The impact continues to compound across the business,” said Jeff Durham, CEO of Durham Brands.

Durham Brands has experienced more than 30% year-over-year growth for several consecutive years, supplying major retailers including Target, Walmart, Kroger and Ulta. As order volumes, SKU complexity and warehouse footprint expanded, the company outgrew its legacy warehouse management system, which relied heavily on manual processes and disconnected workflows across picking, packing and shipping.

Through Infios WM, Durham Brands introduced system-directed workflows across picking, license plating, lot control, and scanning – within a unified fulfillment environment. These capabilities eliminated manual steps, reduced mis-ship risk and improved real-time visibility across operations.

The system’s intuitive workflows and NetSuite integration have empowered employees across the operation – including a hearing-impaired, Spanish-speaking team member who now independently manages e-commerce fulfillment.

Durham Brands also strengthened inventory control and financial performance by moving to continuous cycle counting and improving lot visibility, enabling more strategic sourcing decisions and generating hundreds of thousands of dollars in tariff savings.

“Durham Brands’ results demonstrate how intelligent supply chain execution can unlock new levels of performance at scale,” said Tim Moylan, Chief Growth Officer, Infios. “The team is now completing a full week of work in just three days while maintaining exceptional accuracy and throughput. This is exactly the kind of continuous optimization and agility modern supply chains require to keep pace with growth.”

With a scalable, modern warehouse management platform in place, Durham Brands is now positioned to sustain its rapid growth while maintaining high service levels, operational efficiency and workforce productivity. The company plans to continue investing in automation, data visibility and scalable infrastructure to support its next phase of growth.

New Warehouses: Human-Optional/Robot-Centric

By 2030, 50% of new warehouses in developed markets will be designed as ‘robot-centric’ facilities, with humans being optional, according to Gartner.

As warehouse workers become less keen to perform manual tasks, many organizations will be challenged to sustain operations through hiring alone, as labour costs and supply remain under significant pressure for most of the year. In response, chief supply chain officers (CSCOs) are accelerating adoption of intralogistics smart robotics (ISRs) to scale operations as manual labour warehouse models become increasingly obsolete.

“AI continuously optimizes warehouse environments in real-time, shifting them from static structures into agile systems that adapt as demand changes,” said Abdil Tunca, Senior Principal Analyst in Gartner’s Supply Chain practice. “This changes how CSCOs think about designing warehouses for scalability, from settings that primarily rely on human labor to environments that maximize the ability to orchestrate robotic fleets.”

The ISR market is highly fragmented and will require most companies to adopt more than one type of robot and a multiagent orchestration platform to coordinate heterogenous fleets of robots. As robot adoption accelerates, organizations are moving beyond retrofitting traditional facilities with automation to designing new warehouse environments. In these modern warehouses, human labour is required only for exception handling, rather than serving as the foundation of daily operations.

Workforce and Cost Pressures Are Driving a Shift to AI Orchestrated Operations

Warehouse designs will increasingly prioritize flexibility, efficiency and adaptability to support automation-led, human-aided workflows. Workstations, storage of goods and fulfillment workflows can be adjusted instantly based on changes in demand patterns or labour availability, allowing facilities to respond without costly physical redesigns.

Over time, fixed warehouse infrastructure will give way to more software managed environments that continuously self optimize. For example, re-routing robotic pickers to higher priority orders during peak demand or reallocating tasks between humans and machines when staffing levels fluctuate.

This shift enables organizations to scale operations more efficiently. Autonomous facilities can operate with reduced lighting and climate requirements and reconfigure workflows without physical infrastructure changes. While there will be upfront capital costs, automation offers structural cost advantages that can help organizations handle higher order volumes with lower costs.

Gartner recommends CSCOs take the following steps when designing robot centric warehouse environments:

● Adopt digital twin and simulation models early to validate layouts and optimize robotic performance prior to construction.
● Favour scalable, software defined robotics platforms over single purpose automation to improve adaptability and reduce obsolescence risk.
● Establish long term vendor ecosystem partnerships to support future integration, flexibility and expansion.

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