How Barrett Is Improving Inventory Accuracy with AI-Powered Warehouse Visibility

Faith Artieda • May 26, 2026

How Barrett Is Improving Inventory Accuracy with AI-Powered Warehouse Visibility

At MODEX, Barrett Distribution joined Gather AI to discuss a challenge every warehouse operator understands: keeping inventory accurate while meeting rising ecommerce expectations.


As order volumes grow and fulfillment windows shrink, traditional inventory management processes become harder to scale.


 Barrett’s operations team shared how they’ve used Gather AI’s drone and vision technology to improve inventory visibility, reduce manual work, and support faster, more accurate fulfillment across their network.

The Challenge: Inventory Accuracy at Scale


Barrett manages millions of SKUs across multiple facilities and customer profiles. Maintaining inventory accuracy at that level requires constant visibility into where products are located and whether inventory records match what’s physically in the warehouse.


Historically, that meant large cycle counting teams using RF scanners and lift equipment to manually verify inventory throughout the day.


The process worked — but it came with challenges:

  • Labor-intensive cycle counting
  • Increased equipment usage
  • More associate traffic in warehouse aisles
  • Slower inventory verification
  • Difficulty keeping pace with ecommerce demand


For Barrett, inventory accuracy directly impacts customer experience. If inventory isn’t where it’s supposed to be, orders can’t ship on time and accurately.


As Jim Rapoza, Barrett’s VP of Business Process Optimization, explained:


“People want to do their job and they want to do it well. If the product is not where it belongs, they can’t.”


Why Barrett Partnered with Gather AI


After evaluating several technology providers, Barrett selected Gather AI to help modernize inventory management processes.


Gather AI’s solution uses autonomous drones and AI-enabled vision systems to scan warehouse inventory and verify product locations much faster than manual processes.


Instead of relying solely on associates to cycle count inventory, drones can continuously scan warehouse aisles and compare physical inventory against WMS data in near real time.


According to Rapoza, the partnership stood out early:


“Gather AI’s technology, their vision, and just as importantly, their customer service and partnership was light years ahead.”


Results Barrett Has Seen


Barrett shared several measurable improvements since deploying Gather AI across 10 facilities.


Improved Inventory Accuracy


Some facilities have achieved near-perfect inventory accuracy levels after implementing the technology.

  • Benefits include:
  • Better order fulfillment accuracy
  • Faster issue resolution
  • Reduced inventory shrink
  • More reliable shipping performance


Faster Inventory Scanning


Compared to manual counting methods, Barrett has seen major increases in scan productivity.


In certain high-density storage environments, drones can complete up to:

  • 2,000 scans per hour
  • 200%–400% faster scanning rates compared to manual processes


Reduced Labor Requirements


  • By automating portions of the cycle counting process, Barrett reduced labor spend related to inventory counting by approximately 40%.
  • The company also reduced reliance on additional material handling equipment previously used for manual counting activities.


Beyond Drones: Real-Time Warehouse Visibility


Barrett is also piloting Gather AI’s Material Handling Equipment (MHE) Vision platform. The system mounts AI-enabled cameras directly onto forklifts and warehouse equipment to track inventory movement throughout the facility.


This allows operations teams to:

  • Automatically verify inventory moves
  • Improve traceability
  • Reduce manual scanning steps
  • Improve warehouse visibility in real time


Instead of auditing inventory after the fact, the goal is to create continuous visibility throughout the fulfillment process.


Operational Benefits Beyond Accuracy


One unexpected benefit Barrett discussed was improved operational discipline inside the warehouse. Because the technology depends on visible labels and proper pallet placement, teams naturally maintain cleaner, more organized storage practices.


That operational consistency supports:

  • Faster picking
  • Better replenishment flow
  • Improved productivity
  • Higher employee satisfaction


Rapoza noted:“The technology needs to see the license plate. It enforces really great aisle hygiene and operational discipline.”


Looking Ahead


As fulfillment operations become more complex, inventory visibility is becoming increasingly important for 3PL providers.


Barrett’s partnership with Gather AI reflects a broader shift happening across the logistics industry:

  • More automation
  • Better real-time visibility
  • Faster decision-making
  • Improved fulfillment accuracy
  • Scalable warehouse operations


For Barrett, the focus remains the same: delivering reliable, accurate fulfillment while continuously improving operational performance for customers.

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