Stop Racking Up Costs: Transforming Warehouse Storage Health with Dexory
One of my first jobs in warehousing wasn’t a glamorous one. I would get lifted by a forklift in a cage and manually count inventory on the upper levels. What made this particularly unpleasant was doing this in the freezer and getting blasted by the chillers. I wasn’t just counting up there; I was finding damaged pallets, identifying risks, locating loose product, and, in hindsight, building character.
The higher the racking goes, the harder it is to see what’s happening from the floor. For instance, a damaged pallet creates problems across safety, inventory, labor, compliance, and customer service. Floor walks and employee reporting often can’t find issues that may be high in the rack or hidden from normal view. Enter the tallest robot in warehousing.
Dexory’s Storage Health helps teams detect damage earlier and shift from reactive correction toward proactive warehouse product damage prevention.
Revealing the Warehouse Visibility Gap
Inventory accuracy answers two important questions: Is the stock in the expected location, and is the expected quantity there? It does not confirm that the pallet, product, or storage location remains in acceptable physical condition.
Matthew Smith, Senior Product Manager at Dexory, explains, “We knew that there was a gap in terms of our offering and what the market was providing in terms of ensuring stock and the location housing that stock was in the right condition.” That gap creates costs that may not appear as a single line item. Damaged pallets can interfere with putaway and retrieval, create health and safety concerns, increase quality-assurance work, and allow product damage to travel downstream to the customer. Smith notes that condition issues can affect “putaway activities, retrieval, compliance, regulatory overheads, and quality assurance.”
The problem is also difficult to solve through occasional observation alone. Large facilities, high rack levels, and constant product movement make it easy for defects to remain unnoticed. As Smith says, “The origins of this area, this kind of feature set really came through customer conversations.” Across different operations, customers were consistently asking for visibility beyond location and quantity.
Dexory Warehouse Storage Health Extends Visibility Beyond Inventory Accuracy
Dexory Storage Health uses the images already captured during autonomous robot scans to assess warehouse conditions as part of normal operations. Rather than requiring a separate inspection route, the software adds an AI-powered analysis layer that identifies exceptions and directs attention to locations that may require action.
Smith explains, “The feature detects damage to racking, damage to pallets, and tipping items.” It also detects crushed or indented cases, hanging shrink wrap, and empty pallets. The robot may be the most visible part of Dexory’s platform. However, Smith emphasizes that “most of the customer experience and certainly the value sits in the insights.” Collecting images is useful; converting those images into recognizable issues is what helps warehouse teams respond.
Early customer feedback suggests that continuous visibility is exposing conditions that traditional checks missed. Smith says, “Customers are broadly reporting they are detecting more cases to remediate and to fix.” He adds that customers are “finding things that we were unaware of.” For warehouse leaders, the hidden cost of damage begins with a more basic problem: The organization may not know the damage exists.
Storage Health wins Best New Innovation at the 2026 MHI Innovation Awards
From Detection to Proactive Warehouse Product Damage Prevention
The value of Storage Health is not simply that it finds more issues. It shortens the time between a problem developing and the warehouse becoming aware of it. Because many Dexory customers scan wall to wall daily, Smith says “issues are being picked up more quickly,” and stock that is slumped or tipping is not left “in a perilous state for long periods of time.”
Earlier detection allows operations and safety teams to intervene before damaged pallets contribute to product loss, process disruption, or a more serious incident. It can also strengthen operating discipline. Smith says customers are beginning to see workforce behavioral changes because teams “know that they’re even more accountable for being prudent and keeping things in good condition.”
That creates a shift from observation to prevention. Management teams are beginning to connect how technology can “support on the preventative side of things” and help realize “cost avoidance.” Dexory is also integrating Storage Health results into its task-management workflow so teams can assign, prioritize, and comment on remedial actions.
As Smith explains, “It’s not sufficient purely to be a reporting tool and to flag a bunch of insights.” The goal is to help warehouses “convert insight into action.”
Proactive Warehouse Storage Health with Dexory
Damaged pallets will never disappear completely, but the time they remain unseen can be reduced. By combining autonomous scanning, computer vision AI, and actionable workflows, Dexory Storage Health helps warehouse leaders protect product integrity, strengthen safety, and address conditions before they become higher operational costs.
Learn more about Dexory’s Storage Health feature and how continuous condition visibility can support proactive warehouse product damage prevention.
