Plug In and Optimise: How Medusa Distribution Transformed Picking, Packing, and Shipping with Lucas Systems and Perseuss

In today's accelerated fulfillment world, efficiency isn't just a pleasant. It's a requirement. Labor shortages, unpredictable demand, and rising shipping cost are prompting warehouse operators to think about rethinking the way they pick, pack, and ship orders.

That is exactly what Medusa Distribution decided to tackle head-on. In a recent webinar hosted by Logistics Manager, leaders from Medusa Distribution, Lucas Systems, and Perseuss shared how advanced cartonization software and real-time dynamic picking helped them achieve big gains in productivity and cost savings.

Here is a look at how it all came together.

Discover how Perseuss cartonization software and Lucas Systems help Medusa Distribution boost productivity, cut shipping costs, and streamline picking and packing. Learn how advanced cartonization, real-time optimisation, and smart batching transform fulfilment operations.

Moving From Manual Packing to Smart, Real-Time Decisions

When Andrew Haner, the Chief Operations Officer at Medusa, joined the team, the warehouse still relied heavily on paper processes and “tribal knowledge.” Pickers were making decisions from memory about which boxes to use, what items could be shipped together, and how to follow carrier rules.

Naturally, mistakes were common and packing was inefficient. The company was also struggling with high shipping costs and labor expenses. Onboarding new team members was slow because it took a long time to learn all the unwritten rules.

Medusa needed a smarter way to work. They wanted a solution that could:

• Automate cartonization decisions with reliable cartonization software

• Guide pickers step by step in real time

• Scale easily without requiring expensive equipment or heavy automation
  

Perseuss: Reimagining Cartonization Software

This is where Perseuss stepped in. Thomas David Ye, founder of Perseuss, spent years working on Amazon’s supply chain systems before launching his company. He knew most warehouse management systems include basic cartonization, but the logic is often limited.

Standard WMS cartonization tools usually look only at volume. They might fit everything into a box without considering how shipping rates, surcharges, and packing restrictions affect the final cost.

Perseuss takes a more advanced approach with cartonization software that:

• Runs simulations to test different ways to pack and ship orders

• Compares carrier-specific shipping rates and restrictions

• Factors in rules for fragile items, hazmat shipments, and “no-fly” zones

Tomas explained it like this during the webinar:

“You can model and simulate orders in detail. You can decide how to pack them in a way that lowers costs and follows all the rules. Most WMS cartonization logic stops at volume. Perseus goes much deeper.”

Lucas Systems: Turning Decisions Into Action

Even the best cartonization software cannot help if pickers do not have clear instructions. That is where Lucas Systems came in.

Lucas brought in their Jennifer voice-directed technology, which guides pickers step by step. With Jennifer, pickers can work hands-free while the system tells them exactly what to pick and where to place it.

Instead of picking items into a tote and re-packing them later, pickers now place products directly into the correct shipping cartons as they go.

Andrew Haner, the COO of Medusa Distribution, summed it up well:

“Our pickers are now also our packers. We removed an entire touch from the process and cut down on errors.”

The Results Speak for Themselves

Combining Perseus cartonization software and Lucas Systems delivered measurable improvements almost immediately:

• 14% increase in units picked per hour, thanks to voice-directed, hands-free picking

• 20%+ productivity gains among the most experienced pickers

• 16% reduction in shipping costs, driven by smarter packing and carrier rate optimization

• Faster turnaround, with most orders picked, packed, and ready to ship the same day

• Simplified onboarding, since new team members no longer have to memorize all the old packing rules
  

These results show what is possible when you bring advanced cartonization software and dynamic work optimization together in one workflow.

Perseus cartonization software + Lucas Systems: Higher productivity, lower costs, and faster fulfilment in one streamlined workflow.

Why This Matters for Modern Warehouses

Medusa Distribution’s story is a great example of how warehouses can move beyond static processes. Traditional WMS setups rely on batches of orders released in waves. They also depend on people making judgment calls on how to pack.

By combining real-time data, advanced cartonization software, and voice-directed picking, Medusa built a more flexible and resilient operation.

Rick Day from Lucas Systems shared:

“A dynamic warehouse environment helps you adapt to any challenge in real time. Whether it is labor shortages, cost increases, or sudden demand spikes, you are ready.

Watch the Full Webinar

If you want to see the full story, you can watch the webinar replay here:

🎥 Watch Webinar

You will hear directly from Medusa, Lucas Systems, and Perseus about how they partnered to create a warehouse process that is faster, more accurate, and more cost-efficient.

Ready to See What Advanced Cartonization Software Can Do?

If you are looking for ways to optimize your picking, packing, and shipping, now is the time to explore solutions that combine cartonization software with dynamic work optimization.

Reach out to Lucas Systems or Perseus to learn how this approach can help your warehouse improve accuracy, save on shipping, and deliver a better experience to your customer

Schedule Meeting with Perseuss