When Systems Connect, Magic Happens

Three systems. One workflow. One incredible result for Medusa Distribution.

When the right systems connect, something special happens. Processes simplify. Teams move faster. Costs go down. And warehouses turn into powerhouses.

That’s exactly what happened when Medusa Distribution, Lucas Systems, Deposco, and Perseuss came together to reimagine how a fast-growing operation could scale without sacrificing efficiency or customer experience.

The Challenge

Medusa Distribution is one of the leading distributors of vaping products in the United States. Their operation is anything but simple.

They manage:

• A large and diverse SKU portfolio (10,000+ SKUs)

• Highly complex order profiles, from single-unit DTC eCommerce orders coming from Shopify to multi-parcel FedEx shipments and full LTL pallet shipments with Old Dominion Freight Line

• A regulated shipping environment, limiting carrier options and increasing costs

  
  

Additionally, Medusa is experiencing rapid growth. The challenge was clear:

How do you support explosive growth without exploding costs, headcount, or operational complexity while still delivering an exceptional customer experience?

The Solution

The breakthrough came from simplifying the workflow and letting each system do what it does best.

Medusa transitioned from a traditional pick-to-tote process, followed by tote-to-carton packing, to a streamlined pick-to-carton workflow.

This single change had a massive ripple effect:

• Packing stations were no longer bottlenecks

• Packers could focus only on exceptions

• A portion of the packing workforce was redeployed to support the growing volume of picking tasks

  
  

Here’s how the connected workflow works:

1️⃣ Deposco WMS receives all orders directly from Medusa’s website and Shopify

2️⃣ Perseuss applies AI-powered cartonization to determine the optimal number of cartons and item placement, minimizing shipping cost while honoring hundreds of custom packing rules

3️⃣ Lucas Systems executes the plan on the warehouse floor, where its voice AI agent Jennifer guides pickers through the most efficient pick path and enables true pick-to-carton execution

There are multiple layers of optimization happening at once, and together, they create something powerful.

The Results

The impact was immediate and measurable:

• 📊 13% increase in picking UPH

• 💰 16% reduction in shipping costs

• 📉 30%+ reduction in cost per unit

• 📦 89% of boxes packed perfectly during picking and ready to ship

  
  

That last metric deserves special attention.

Achieving 89% pick-to-carton accuracy for:

• Orders averaging 100+ units

• Orders averaging 2+ cartons

• A catalog of 10,000+ SKUs

• Hundreds of custom packing rules

…is no small feat.

Not only did this eliminate 40%+ of unit touches, but it also laid the foundation for an automated print-and-apply initiative planned for 2026.

The Power of Collaboration

This wasn’t just a software upgrade. It was a true, multi-company collaboration.

From system architects and engineers to warehouse operators and project leaders, it took an incredible group of people to bring this vision to life.

We’re deeply thankful to the teams and individuals who made it happen

And the amazing teams at Medusa, Lucas Systems, Deposco, and Perseuss.

Looking Ahead

This project wasn’t about adding more tools or complexity. It was about connecting the right systems and letting each one do what it does best.

By aligning Deposco, Perseuss, and Lucas Systems into a single pick-to-carton workflow, Medusa has built an operation designed to scale efficiently with fewer touches, lower costs, and greater consistency across every order.

With accuracy already exceeding expectations, this foundation also sets the stage for what comes next, including automated print-and-apply initiatives planned for 2026.

The systems are connected. The workflow is proven, and the operation is ready for continued growth.