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.

Recent Blog Posts

A Perfect Fit: RateFit Chooses Barrett Distribution Centers

By Faith Artieda • July 10, 2026
FRANKLIN, Mass., June 8, 2026 — Barrett Distribution Centers , a leading third-party logistics provider specializing in eCommerce fulfillment, announced a new partnership with RateFit , a Chicago-based athleisure brand under the Rate.com family of companies. “From the beginning, Barrett demonstrated the experience and capabilities we were looking for in a fulfillment partner,” said Jenny Sepulveda, president of RateFit. "During our visit, we were impressed by the scale of Barrett's operations and the team's ability to support our long-term growth plans. As we launch, it was important to find a fulfillment partner with apparel expertise, room to scale and the flexibility to support future value-added services." RateFit is a new business under the Rate.com umbrella. Inspired by the concept of living the 'Rate Life,' the brand offers an athleisure collection designed to transition seamlessly from recreational activities to everyday wear. “We’re super excited that the RateFit team chose Barrett to help launch their new brand,” said Harrison Smith , director, 3PL pricing and contract analytics at Barrett. “It’s been a pleasure working with Jenny and Mia throughout this process. With their passion and expertise in the space, I have no doubt it will become one of the leaders in the athleisure market, and we’re thrilled they trusted Barrett to be part of their journey.” RateFit is now live at one of Barrett’s Memphis, Tenn., fulfillment facilities, where Barrett provides direct-to-consumer fulfillment and parcel shipping services. The partnership supports the launch of RateFit’s which offers versatile apparel designed for everyday life from the studio to the office, coffee, and everything in between. Barrett’s fulfillment capabilities will help the brand efficiently serve customers nationwide as it scales its direct-to-consumer business. Barrett's Memphis operation is part of a nationwide fulfillment network supporting high-growth consumer brands across multiple industries. About RateFit RateFit is a Chicago-based athleisure brand under the Rate.com family of companies. Inspired by a wellness-focused lifestyle, the company offers versatile apparel designed for everyday life from the studio to office, coffee, and everything in between. Its collection combines performance, comfort and style to support consumers both on and off the course. About Barrett Distribution Centers Since 1941, Barrett has provided customized third-party logistics (3PL), direct-to-consumer (DTC) eCommerce fulfillment, omnichannel distribution, managed transportation solutions and retail compliance for clients across all industries, with a focus on apparel & footwear, health & beauty, consumer packaged goods (CPG) and education. Barrett continues to be a leading 3rd party logistics provider in North America, known for superior execution, customer engagement and direct access to senior leadership decision makers. As a member of Inc's fastest growing companies list 15+ times, Barrett is big enough to do the job and still small enough to deeply care about your business. Brands interested in a new 3PL partnership may contact Barrett directly here . Official Release Here Media Contact: Faith Artieda Marketing Content Specialist Faith.artieda@barrettdistribution.com

What Is Omnichannel Fulfillment?

By Faith Artieda • July 9, 2026
Your ecommerce business is thriving. Orders are flowing in through your Shopify store, Amazon sales continue to climb, and then it happens—you land your biggest opportunity yet: a purchase order from a major retailer like Walmart, Target, or Costco. It's the kind of milestone every growing brand works toward. But for many businesses, it's also where fulfillment becomes significantly more complicated. Suddenly, you're managing multiple sales channels, each with its own shipping requirements, inventory demands, compliance standards, and customer expectations. What worked when you were shipping directly to consumers may no longer be enough to support retail distribution. This is where omnichannel fulfillment becomes essential. In the first episode of Inside Barrett with Faith Artieda , Barrett's Senior Vice President of Customer Solutions, Scott Hothem , explained that omnichannel fulfillment isn't simply about shipping products through multiple channels—it's about having the operational expertise to manage every channel successfully while maintaining a consistent customer experience. More Than Shipping Orders Many people assume omnichannel fulfillment simply means offering multiple ways for customers to buy products. While that's true from the consumer's perspective, the logistics behind those purchases are entirely different. A customer placing an order on your website expects fast, accurate delivery to their front door. That order may include just one or two items that need to be individually picked, packed, and shipped. A retailer, on the other hand, might place a purchase order for thousands of units. Those shipments often require palletization, retailer-specific labels, advance shipment notifications (ASNs), routing guide compliance, scheduled delivery appointments, and strict packaging requirements. Missing even one requirement can result in costly chargebacks or delayed deliveries. "The channels are very, very different," Scott explained during the interview. "How you manage inventory is different. Those retailers often want unique SKUs that you don't sell on your primary direct-to-consumer website." Although both orders originate from the same inventory, they require completely different operational workflows. Growth Creates Complexity For many brands, expanding into retail feels like the natural next step—but it also introduces new challenges. Inventory must remain synchronized across every sales channel. Technology systems need to communicate seamlessly. Customer expectations continue to rise, and retailers demand near-perfect compliance. Without the right fulfillment strategy, brands can quickly become overwhelmed. That's why Scott believes the role of a 3PL extends far beyond storing inventory and shipping packages. At Barrett, the goal is to help brands navigate these transitions before they become problems. Whether a company is launching its first retail partnership or rapidly scaling its ecommerce business, Barrett works alongside customers to build fulfillment solutions that evolve with their growth—not solutions they'll outgrow in a year or two. As Scott put it during the interview, Barrett strives to become a brand's " forever 3PL " by supporting customers through every stage of their journey. Omnichannel Is About Visibility, Flexibility, and Partnership Successful omnichannel fulfillment requires much more than warehouse capacity. It depends on real-time inventory visibility, seamless technology integrations, retail compliance expertise, transportation management, and a fulfillment operation capable of adapting as customer demand changes. It also requires a logistics partner that understands your business well enough to anticipate challenges before they impact your customers. That's the approach Barrett has taken for more than 80 years. Rather than offering a one-size-fits-all fulfillment model, Barrett designs customized omnichannel solutions that allow brands to manage direct-to-consumer, wholesale, marketplace, and retail fulfillment through a single, integrated operation. With expertise in retail compliance, transportation management, value-added services, and advanced warehouse technology, Barrett helps brands simplify complex supply chains while preparing for future growth. Looking Ahead Today's consumers don't think about fulfillment channels—they simply expect their orders to arrive on time, regardless of where they made the purchase. For brands, meeting those expectations requires more than great products. It requires a fulfillment strategy built to support every channel, every customer, and every stage of growth. As Scott shared in Inside Barrett , the right 3PL doesn't just help you fulfill today's orders. It helps prepare your business for tomorrow's opportunities. And that's what omnichannel fulfillment is really all about.

How Do I Know If It's Time to Switch 3PLs?

By Faith Artieda • July 7, 2026
Switching third-party logistics (3PL) providers isn't a decision most businesses take lightly. It requires time, planning, and trust. But staying with the wrong partner can cost even more—through missed shipments, unhappy customers, and lost opportunities for growth. So how do you know when it's time to make a change? One of the biggest signs is when your 3PL starts holding your business back instead of helping it move forward. Maybe customer service has become difficult to reach, order accuracy has declined, or you're constantly following up on issues that should have been resolved proactively. Your fulfillment partner should give you confidence, not create more work for your team.  Growth is another common reason brands switch providers. A 3PL that worked well when you were shipping a few hundred orders each week may not have the systems, technology, or expertise to support new retail partnerships, higher order volumes, or omnichannel fulfillment. As your business evolves, your logistics partner should evolve with it. It's also worth evaluating how your 3PL approaches the relationship. Do they take the time to understand your goals and recommend improvements, or are they simply processing orders? The best providers act as an extension of your business, offering strategic guidance, transparent communication, and solutions designed to support long-term success. At Barrett Distribution Centers, we believe a successful partnership starts long before the first shipment leaves the warehouse. That's why we invest time upfront to understand each customer's business, design a customized fulfillment strategy, and build solutions that can scale as your company grows. Rather than focusing on short-term transactions, our goal is to become a long-term logistics partner that supports your business through every stage of growth. If your current 3PL is creating more challenges than solutions, it may be time to ask whether they're still the right fit. The best fulfillment partner isn't just the one that ships your orders—it's the one that helps your business grow with confidence.
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