Case Study: Apex Tool Group achieves 63% fewer picking errors with Lucas Systems

Apex Tool Group Addresses Labor Needs with Lucas

Apex Tool Group, LLC, a leading global manufacturer of professional tools, faced significant labor shortages and inefficient, error-prone picking processes at its large North Carolina distribution center. To address these challenges and meet stringent customer quality demands, ATG partnered with Lucas Systems to implement its AI-powered warehouse optimization solution, which features the Jennifer voice-directed orchestration engine.

The Lucas solution introduced multi-modal, voice-directed picking, AI-based batching, and path optimization to streamline workflows and replace outdated RF and pick-to-light technology. This resulted in a dramatic 63% reduction in picking errors and a 10% reduction in overall man-hours, allowing the DC to maintain high service levels with a smaller workforce. The efficiency gains and improved process simplicity were highly praised by associates, making the implementation a success for both the workers and the business.

Apex Tool Group, LLC

Chris Rufa

Senior Director of Global Distribution