Most AMR picking systems lock you into a single picking strategy for the entire warehouse. But Performance Health wanted precision, not a one-size-fits-all setup.

With OMRS Intelligence, they now run two intelligent pick modes concurrently, each one configured aisle-by-aisle based on real-world factors like product velocity, order type, aisle width, and SKU density. Jaunzemis says: “Much of the magic is in the way the Chuck system controls and optimizes the pick paths. It makes for a very dense pick pattern, and that is what drives much of the productivity.”

“The flexibility of tuning pick modes by aisle gave us options – we weren’t boxed in. We could match the mode to the need in the software, and that made all the difference”

The OIA team worked closely with Performance Health to assign the right mode to each aisle, optimizing for throughput, predictability, and traffic flow. The two modes deployed were:

Sweep

This is where associates stick with their bot as it guides them through the aisle, end to end. OMRS Intelligence uses dynamic zoning algorithms to calculate whether switching bots will add measurable value, and only swaps if it does. Handoffs most commonly happen at the end of an aisle.

Sweep powers most of Performance Health’s warehouse, especially in narrow or high-density aisles, and continues to deliver best-in-class results.

TagTeam

In wider aisles with mid-density SKUs, Performance Health uses TagTeam. This is where associates work across multiple bots within the aisle, positioned at traffic-free pick-locations. Like Sweep, TagTeam uses dynamic zoning to decide if and when to switch bots. Handoffs most commonly happen mid-aisle.

This smarter, more controlled flow avoids the chaos of swarm-style systems that flood aisles with bots leading to congestion, blockages, and unpredictable task switching. TagTeam enables controlled movement and intentional handoffs to keep operations smooth, even at scale.

The ability to tailor pick modes by aisle played a key role in delivering the above results. This flexible approach unlocked additional productivity that a one-size-fits-all method would have left on the table. Early indications show this delivered a productivity uplift of around 10%.

“The flexibility of tuning pick modes by aisle gave us options – we weren’t boxed in. We could match the mode to the need in the software, and that made all the difference,” says Hetzler.

One of the biggest gains from Project Jesse has been the seamless integration of Chuck AMRs with OMRS Intelligence, orchestrating the entire pick-and-pack process. 

Chuck AMRs now carry shipping cartons cut to size by Packsize machines, with pickers following clear on-screen and light-guided instructions to place items directly into right-sized cartons in the correct shipping sequence.

Jaunzemis recalls the difference: “These systems have taken what I would call the chaos and congestion out of our job. Before, we might have close to 100 bread carts being moved by pickers at any given time, running all over the building, and now we have 32 of OIA’s Chuck AMRs helping to execute those picks, but the congestion and chaos is gone. If you were to walk onto the warehouse floor, you might even think it’s not that busy, because the robots are out helping our pickers in the aisles. The system has really changed the environment that we work in and improved the culture of the workplace.”

The orchestration between Chuck and Packsize is what makes this possible. OMRS Intelligence sends package dimensions ahead, cutting a right-sized carton with no need for scanning.

Each custom-fit box is ready just in time and placed on the Chuck, so items can be picked directly into it in shipping order.

“We print the pack slip at the point of pick. No scanning. No rescanning. It just works,” adds Ryan Hetzler, Director of Operations.

Since every box is perfectly sized, up to 20% more orders fit on each Chuck cart, further boosting density and throughput. More than 3,000 unique box sizes are now produced, eliminating wasted space and void fill.

The impact extends well beyond efficiency: fewer cartons per order, fewer trucks required, and a smaller carbon footprint. “Today, customers receive fewer boxes per order on average, resulting in a more streamlined and efficient delivery experience. From a sustainability perspective, this also translates to fewer truckloads in our distribution network and reduced materials handling on the customer end,” Jaunzemis explains.

With Chuck AMRs and the OIA software in place, Performance Health moved from reactive fulfillment to continuous optimization. OIA’s system now collects and analyzes operational data in real time, automating formerly manual tasks like slotting, routing, and performance planning. 

For example, slotting exercises that used to happen once a year in an Excel spreadsheet are now run monthly on-demand. The system highlights top-performing SKUs, recommends ideal pick-front locations, and even calculates the ROI of re-slotting changes, all autonomously.

“We achieved ROI in under a year. Chuck helped us grow without compromise,” notes Jaunzemis, regarding the swift payback on this project.

“Chuck also acts like a floor supervisor, assigning the most efficient tasks and eliminating unnecessary walking,” adds Hetzler, highlighting how intelligent automation optimizes the workforce.
This smarter fulfillment model enabled Performance Health to scale throughput using the same staff and the same facility footprint, even during peak season. 

“We just came out of our first peak season with Chuck AMR, and it was like peak didn’t occur. We kept asking ourselves when it was going to get chaotic, and it didn’t happen,” Jaunzemis reports.

In other words, the system handled peak volumes so well that peak felt no different than any other week. 

“The ROI spoke for itself. Productivity gains were clear – higher quality, less labor, and scalable growth without just adding people,” adds Hetzler.

In fact, ROI was officially achieved in less than one year, about six months sooner than initially expected, thanks in part to continuous software updates that kept improving performance.

Performance Health eagerly adopted every new release of the fulfillment software, and saw performance rise with each update. Over 12 months, software enhancements alone delivered a 23% increase in units picked per hour (UPH). As OMRS Intelligence evolved through regular releases, the operation unlocked new capabilities without disruption or additional investment.

The extra picking capacity gained from these software-driven improvements allowed the team to take on new workflows, like putaway and LTL (less-than-truckload) order fulfillment, with the same workforce and infrastructure.

“This isn’t a static solution. The team is constantly pushing innovation. Now we use Chuck for putaway too, which we didn’t even plan for initially. We’re also shifting our LTL shipments onto Chuck. Exception slips now print automatically. I could go on for hours!” says Hetzler, emphasizing how the solution continues to expand in capability over time.

Chuck robots now even assist with handling oversized LTL orders that are too large for standard parcel processes but don’t require a full pallet load, proving the robots aren’t just for small-item picking. All of this was accomplished using the original fleet of 35 Chucks – no additional robots needed.

“That’s taken a truck out of the aisles, and it’s doubled our putaway productivity,” Jaunzemis explains.

The robots not only increased output but also transformed the workplace culture. By taking over the long walks and cognitive load of routing decisions, associates now experience less fatigue and greater job satisfaction.

“The system reduced fatigue, improved pick density, and gave our team confidence,” says Jaunzemis, reflecting on the workforce benefits. 

Instead of rushing around the warehouse, employees can now focus on accurate picking while the automation handles navigation and box prep. 

“The system-directed workflow means our team doesn’t waste time wondering what’s next. Chuck tells them where to go. It improves both confidence and output,” Hetzler adds. 

The technology not only makes the work easier, but also helps employees feel more successful in their roles.

OIA went further by sending a Chuck to Performance Health weeks ahead of go-live. The early exposure gave associates time to train and build confidence. The result was higher morale, faster adoption, and a smoother launch.

Full deployment was achieved in roughly two weeks, far ahead of schedule, with minimal disruption to ongoing operations.

The solution was intentionally designed for quick deployment, and it paid off: 

“We planned a slow rollout, six Chucks per week, but by week two, all 35 were up and running. The team hit their pace right away,” Hetzler notes on the fast ramp-up. 

Importantly, no infrastructure changes were needed to accommodate the robots. “We did not have to change the infrastructure of the building to accommodate the mobile robot fleet,” Jaunzemis confirms.

The Chuck system was designed for simplicity. Instead of clunky RF guns and static pick lists, associates now interact with touchscreen tablets and light guidance on the robots.

“It’s a very easy system to use,” says Jaunzemis. “Most people would be picking pretty efficiently with the Chucks after about 15 minutes of training.”

This intuitive design slashed onboarding from two weeks to just two hours. New staff can hit productivity targets by their second day, with no forklift licenses or memorization of function keys required.

Associates simply badge in to the device and follow visual instructions in their preferred language; they can reach productivity targets by their second day on the job, all without needing forklift licenses or extensive training. 

“It’s simple and intuitive. Before Chuck, training took 2–3 weeks. Now new staff are productive by Day 2,” says Hetzler, highlighting the drastic improvement in training efficiency.

Building on the success of Project Jesse, Performance Health has a bold vision for further scaling through full-suite automation. Having seen firsthand how quickly the person-to-goods AMRs and intelligent software delivered ROI, the team is now exploring automation beyond just picking and packing, toward a fully orchestrated end-to-end fulfillment ecosystem.

In particular, they are evaluating OIA’s Porter AMRs to automate heavier case and pallet movement workflows, and the Ocado Storage and Retrieval System (OSRS) to maximize high-density storage and optimize inventory handling. What started with Chuck has unlocked a wider ambition: to streamline the entire operation through a single, integrated automation platform.

“We’re looking at OIA’s Porter AMR and also exploring the OSRS,” notes Hetzler, indicating their roadmap.

It’s clear that Performance Health now views OIA not just as a vendor, but as a long-term partner in building a future-ready fulfillment strategy.