Need to Know

• Software systems help warehouses stay resilient when it comes to accurate picking and shipping.
• Systems can prioritize work, coordinate replenishment, balance labor and sequence equipment activity.
• Warehouse software solutions move toward systems with cognitive abilities.

“Inflated costs for beverages and groceries have consumers consistently switching products and pack sizes to find the best value, requiring warehouses to stay resilient and efficient when it comes to accurate picking and shipping while maximizing labor and meeting On-Time In-Full (OTIF) performance,” he says. “Adding tools that can anticipate space usage based on inbound plans and appointments to the WMS enables warehouses to pace product efficiently.

“For example, slotting agents can map inbound products to the best pick location for rapid deployment, remapping the entire warehouse as needed instead of placing them in any open space,” Getman continues. "If the warehouse is nearly full, yard management tools can also receive trailers at any time and prioritize them to doors or park them in the yard for later unpacking.”

Danny Blessing, senior software consultant at Dematic, Grand Rapids, Mich., similarly notes that as operations manage more flavors, package sizes and promotional products, software must provide real-time inventory visibility, intelligent slotting and efficient product movement. 

“These capabilities help teams manage more frequent replenishment, reduce selection errors and maintain fulfillment speed as product portfolios expand,” he explains. “Greater visibility allows operators to understand where products are stored, how quickly they need to move and which inventory should be prioritized.”

Blessing adds that combined with automation, warehouse software can improve accuracy, reduce product damage and waste, and protect throughput. 

“Reporting also gives supervisors actionable insight into inventory accuracy, aging SKUs, lot status and potential obsolescence so they can address issues before service levels are affected,” he says.

Future waves

Given beverage operations use warehouse software to connect inventory, labor, equipment and order data, experts highlight how these systems can streamline day-to-day and long-range activities.

Dematic's Blessing notes that for day-to-day execution, software systems can prioritize work, coordinate replenishment, balance labor, manage exceptions and sequence equipment activity, giving teams a current view of conditions and helping them respond quickly to changes in demand or availability. 

“AI and advanced analytics are extending those capabilities,” he says. “Rather than simply showing what is happening, these tools can identify potential bottlenecks, anticipate inventory and labor requirements, and recommend adjustments before throughput or service levels are materially affected. 

“Over time, the same data can support longer-range activities such as seasonal forecasting, capacity planning, inventory strategy and automation investment,” Blessing continues. “However, while AI can help guide decision-making, its recommendations should be reviewed and validated by operations teams to ensure they align with business priorities.” 

Blue Yonder’s Getman notes that by coordinating AS/RS, automated guided vehicles (AGVs), AMRs and manual or robotic palletization with inventory and order data, beverage operations can improve visibility, storage utilization and throughput while reducing unnecessary manual handling.

“Beverage companies are using warehouse software solutions to move beyond connected devices and automated execution in ‘smart warehouses’ toward systems with cognitive abilities,” Getman says. “The complexity and volatility of the supply chain require systems that provide proactive, predictive orchestration, working to unify labor, robotics, and inventory that can adapt in real time. 

“A cognitive warehouse leverages predictive AI, machine learning, and agentic automation to anticipate needs before they become a problem, plan labor based on forecasted demand, re-optimize workflows, and treat every resource in the warehouse as a single, orchestrated network in both the near- and middle-term horizons,” he continues.

Getman further explains that the growing demand for physical automation is driving the need for solutions that equip robotics with the flexibility and adaptability warehouses require. 

“Human-automation collaboration is a key focus area, with businesses retraining workers to support robotic systems, moving toward a future where autonomous, AI-driven operations will dominate,” he says. 

“The future of these warehouse activities will rely on solutions that use intelligent agents to direct and optimize operations and enable continuous innovation,” Getman continues. “These points will enable 24/7 operations that balance predictable volume with high-touch, promotional, or important picks.”