States Logistics optimizes picking with LYDIA Voice: Greater efficiency and process reliability in a 3PL environment

Rising order volumes, high pick density and changing customer requirements are part of everyday operations for third-party logistics vendors. Especially in dynamic warehouse environments, paper-based or scanner-supported processes are increasingly reaching their limits. At the same time, pressure is growing to onboard new employees more quickly, reduce error rates and sustainably increase productivity. These are precisely the challenges faced by US logistics service provider States Logistics. Together with EPG (Ehrhardt Partner Group) and ASW Global Consulting, the company decided to implement the voice-directed picking solution LYDIA Voice. The result: significantly increased picking performance, greater process reliability and a noticeable reduction in the workload for warehouse staff. 

States Logistics is one of the established 3PL vendors in the USA, serving a wide range of customers with complex distribution requirements and high shipping volumes. Large-volume orders with many pick positions in particular were increasingly causing limitations in speed and efficiency within the existing RF and paper-based processes. At the same time, fluctuating workforce availability increased the effort required for training and onboarding new employees. "We handle large orders with an enormous number of cartons and a great deal of movement in the warehouse. That is why our primary focus was on increasing productivity," explains Todd Myers, Application Manager at States Logistics. 

Seamless integration into existing processes 

To make picking more efficient and flexible, States Logistics implemented the voice-directed solution LYDIA Voice together with EPG and ASW Global Consulting. The key factor in the decision was the straightforward integration into the existing Infor WMS, as well as the ability to flexibly adapt processes at the workflow level without having to intervene in the core logic of the warehouse management system. LYDIA Voice communicates directly with the ERP and WMS environment and guides employees through all picking processes using voice prompts. The hands-free, eyes-free principle enables focused, ergonomic and safe working, particularly in highly dynamic warehouse areas with long travel distances and high pick density. 

Rapid rollout without interrupting operations 

The implementation was carried out in stages during ongoing operations, with no downtime for existing processes. Rather than a classic big-bang rollout, States Logistics started with a small number of employees in voice picking and gradually expanded usage. 

"I was honestly not sure at first how straightforward the implementation would actually be," Myers describes the initial situation. "We simply could not shut down operations for a day. So we started by equipping a few employees with voice and then gradually brought in additional teams." The results were visible after a short time: "After just the first week, practically all employees were working with voice." 

Concerns about speech recognition in noisy warehouse areas also proved unfounded. "We see no issues whatsoever with speech recognition," Myers adds. "We have radios playing, multiple employees picking simultaneously in the same zone, and yet the system works reliably. LYDIA Voice recognizes only the voice of the individual employee." 

Measurable efficiency gains in day-to-day operations 

With the introduction of LYDIA Voice, States Logistics was able to significantly increase productivity in case picking. At the same time, picking accuracy improved by 68 percent. In addition, the company achieved notable reductions in both training times and overtime. Employee satisfaction in the warehouse also increased noticeably. Particularly in the dynamic 3PL environment, the flexibility of the solution proved to be a decisive advantage. Process adjustments and optimizations could be implemented at short notice without disrupting existing workflows or requiring changes to the underlying WMS. "In the course of the project, new ideas and requirements kept emerging that we had not even considered at the outset," explains Myers. "But we were able to adapt the processes flexibly at any time, without this causing any major issues." 

A scalable foundation for future growth 

For States Logistics, LYDIA Voice today forms a flexible and scalable foundation for the demands of modern 3PL logistics. The deep integration into the existing system landscape, the rapid onboarding of new employees and the high level of process stability support the company in remaining able to respond flexibly to increasing volumes and new customer requirements in the future.