This story originally appeared in the November 2025 issue of Modern Materials Handling.

Revolutionizing Warehousing: The Rise of Wearable Technology

“Don’t send someone out to dig a ditch with a spoon.” These powerful words from Ron May, principal engineer at Lucas Systems, strike a chord in today’s warehousing and manufacturing environments. After four decades in technology, May has witnessed profound shifts in how tasks are managed and executed—consulting wearables included.

The Dual Nature of Wearable Technology

When considering wearables, it’s easy to focus solely on the hardware—smart glasses, voice-activated headsets, or wrist-mounted scanners. However, as noted by industry leaders, understanding the integral software developments is equally essential. Today’s wearables are not merely about the devices; they hinge on sophisticated software capabilities that enhance operational efficiency.

Lior Elazary, CEO of inVia Robotics, highlights a striking reality: “The average warehouse manager makes around 200 decisions a day, but the warehouse system must handle over a million.” This immense gap raises important considerations for optimizing workflow.

Software Solutions: More Than Just Tools

Brands like Zebra Technologies, EPG, and Lucas Systems have introduced systems—often referred to collectively as management consoles—that go beyond task directives. They analyze all operational variables to optimize the workflow, adapting in real-time to enhance fulfillment processes.

Chris Demeo from EPG emphasizes the shift from hardware focus to workflow integration. “This paradigm change ripples through warehouse efficiency, impacting not just internal operations but also logistics down to delivery trucks,” he explains.

Adapting to Dynamic Environments

As operational conditions in warehouses evolve, effective wearables must do more than relay data. “Facilities now resemble high-tech spaceships, optimizing for automation and adaptability,” Elazary notes, underscoring the need for systems that integrate workflows and enhance order fulfillment dynamically.

“Wearables are about resolving issues in real time, navigating an increasingly unpredictable operational landscape,” he adds.

The Evolution of Warehouse Devices

What started as simple navigation tools are now pivotal components of overall warehouse operations. Devices range from voice headsets and wearable scanners to sophisticated tablets and phones. Wes Coleman from Zebra points out that employees bring their tech-savvy expectations from everyday experiences into their work environments.

User Acceptance: Key to Success

User acceptance is crucial for the effectiveness of wearable technology. Factors such as ease of use and quick training are fundamental. Many systems boast intuitive setups that minimize training time, enhancing early productivity for new employees.

Advancements in voice recognition allow for seamless transitions between multiple languages, making devices adaptable for diverse workforces. “The ability to switch languages effortlessly during tasks is essential for today’s diverse teams,” Coleman adds.

Wearables and Intelligent Integration

Today’s wearables don’t function in isolation; they’re interconnected with various systems, including warehouse management (WMS), execution (WES), and control systems (WCS). This networked approach allows for the rapid exchange of information and decisions on the ground level—akin to the edge of edge computing.

May notes, “These devices are becoming increasingly advanced and intelligent, promoting seamless decision-making that empowers warehouse workers.”

The Role of AI in Wearable Technology

AI plays a pivotal role in elevating the capabilities of wearable technology. Elazary explains that while some AI functionalities operate in the cloud, they also significantly add value to wearables through real-time processing and optimization capabilities.

Real-World Success Stories

The efficacy of wearable tech is evident in various success stories across the industry:

• Pet Food Experts: EPG’s voice system tackled challenges such as poor inventory visibility, improving productivity by 38% and achieving 99.9% order accuracy while enhancing employee retention by 20%.
• CarParts.com: Utilizing AI-orchestrated workflows, inVia’s system boosted operational workflow by 400%, significantly enhancing overall output and facilitating quicker onboarding for new hires.
• Republic National Distributing Company: Implementing Lucas’s voice technology doubled picking productivity with an impressive 99.6% accuracy, showcasing the effectiveness of integrating wearables into daily operations.

Looking Ahead

As wearables increasingly manage workflows in real time, the next frontier is the potential for predictive operation loops in warehousing. Demeo expresses the vision: “Imagine wearables evolving to anticipate needs, further refining efficiency.” The horizon for wearables in logistics continues to broaden, promising an exciting future for operational excellence.