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How to Build a Digital Twin for Your Warehouse: Tools, Platforms, and Approaches

Leave a Comment / Articles, Technology / Michael

From Concept to Reality Digital twin technology is no longer a future-state idea. It’s here—and increasingly accessible to warehouses of all sizes. But once you’ve decided you want one, the next big question is: How do I actually build a digital twin? There’s no one-size-fits-all answer. Some companies adopt twins through their WMS provider. Others […]

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Digital Twin Technology for Warehousing: Buzzword or Game Changer?

Leave a Comment / Articles, Technology / Michael

The Rise of Digital Twins in Distribution You’ve probably heard the term digital twin tossed around in WMS demos, automation pitches, or IT strategy meetings. But what does it really mean in a warehouse? More importantly—what can it do? For many in warehousing and distribution, digital twins are no longer just a futuristic concept. They’re

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What Is a Digital Twin? (In Plain English)

Leave a Comment / Articles, Technology / Michael

Let’s Keep This Simple: What Is a Digital Twin? A digital twin is a real-time digital copy of something physical—like a machine, a room, a warehouse, or even a full operation. It’s not just a drawing or a 3D model. It’s connected to live data, so when something changes in the real world, it updates

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A3 Problem Solving: What the Templates Don’t Tell You

Articles, Problem Solving / Michael

If you’ve seen an A3 problem-solving form before, you might think it’s just another Lean tool to fill out and file away. But A3 thinking isn’t about the paper. It’s about the way you solve problems. When used properly, the A3 method can transform how your team works. When misused, it becomes just another document

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Lean Without the Buzzwords: What Actually Works

Articles, Lean Principles / Michael

You don’t need a dictionary of Japanese terms to run a better operation. You don’t need posters plastered on every wall, or consultants walking around quoting Toyota like scripture. You need flow. You need visibility. You need a team that gives a damn—and a way of working that makes sense on a chaotic Tuesday morning,

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Visual Management Boards: What to Track and Why They Matter

5s Visual Management, Articles / Michael

Walk into any high-performing warehouse, factory, or distribution center and you’ll see them: whiteboards filled with color-coded charts, magnets, sticky notes—or digital dashboards glowing on the wall. These aren’t decorations. They’re visual management boards—one of the most powerful, underused tools in Lean. A great visual board: So where do you start? What should you put

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Why Visual Management Matters in Warehousing

5s Visual Management, Articles, Warehouse & Operations / Michael

Warehouses are fast-moving, high-variation environments. You’ve got: Without visual management, you get confusion, errors, wasted motion, and delays. With it, you get: Let’s break that down. 1. Reduces Wasted Time and Motion When workers have to constantly ask “Where does this go?” or “What’s next?”, you’re losing productivity. Visual cues eliminate that. For example: 2. Improves Accuracy

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How to Run a 5S Audit in a Distribution Center

5s Visual Management, Articles / Michael

It’s easy to tidy up a warehouse once—but it’s hard to keep it that way. That’s the core challenge of 5S: sustainability. And the secret to sustaining 5S is the 5S audit—a structured, repeatable way to track progress, hold teams accountable, and identify areas for improvement. Whether your distribution center is new to Lean or

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The Rise of Drones in Inventory Stock Takes: A Fad or the Future?

Articles, Technology / Michael

Are Drones the Next Big Thing in Inventory Management? The warehouse floor is changing fast. Automation. AI. Robotics. And now—drones. What started as a niche experiment is gaining serious traction in inventory management. More and more distribution centers are testing or adopting drones to perform stock takes, aiming to reduce labor, increase accuracy, and boost

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What Is 5S? A Lean Foundation for Order and Efficiency

5s Visual Management, Articles / Michael

In the fast-paced world of warehousing, manufacturing, and distribution, one of the biggest threats to productivity isn’t lack of effort—it’s disorganization. Think about how much time is lost daily searching for misplaced tools, navigating cluttered workspaces, or dealing with inconsistent procedures. These seemingly small inefficiencies snowball into lost hours, reduced morale, and higher operational costs.

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