Customer Case Study · Armada Supply Chain Solutions
Customer Case Study · Armada Supply Chain Solutions
Customer Case Study · Armada Supply Chain Solutions
How Armada and Third Wave’s Shared Autonomy platform delivered 99.94% inventory accuracy and zero safety incidents at Armada’s most operationally complex distribution center.
How Armada and Third Wave’s Shared Autonomy platform delivered 99.94% inventory accuracy and zero safety incidents at Armada’s most operationally complex distribution center.
Customer
Customer
Armada Supply Chain Solutions
Armada Supply Chain Solutions
Site
Site
Romeoville, IL
Romeoville, IL
Duration
Duration
November 2024 – November 2025
November 2024 – November 2025
Fleet Deployed
Fleet Deployed
4 Third Wave Reach Trucks
4 Third Wave Reach Trucks
WMS Integration
WMS Integration
Blue Yonder
Blue Yonder
Customer Case Study ·
Armada Supply Chain Solutions
How Armada and Third Wave’s Shared Autonomy platform delivered 99.94% inventory accuracy and zero safety incidents at Armada’s most operationally complex distribution center.
Customer
Armada Supply Chain Solutions
Site
Romeoville, IL
Duration
November 2024 – November 2025
Fleet Deployed
4 Third Wave Reach Trucks
WMS Integration
Blue Yonder
25,863
25,863
25,863
25,863
Pallets Moved
Pallets Moved
Pallets Moved
3,849
3,849
3,849
Production Hours
Production Hours
Production Hours
99.94%
99.94%
99.94%
Inventory Accuracy
Inventory Accuracy
Inventory Accuracy
90.4%
90.4%
90.4%
Truck Availability
Truck Availability
Truck Availability
0
0
0
Safety Incidents
Safety Incidents
Safety Incidents
4:1
4:1
4:1
Forklift-to-Operator Ratio
Forklift-to-Operator Ratio
Forklift-to-Operator Ratio
Executive Summary
Executive Summary
Executive Summary
A pilot built for the hardest conditions first
A pilot built for the hardest conditions first
A pilot built for the hardest conditions first
In January 2024, Armada Supply Chain Solutions, a leader in modern supply chain orchestration, partnered with Third Wave Automation to launch a one-year autonomous forklift pilot at one of Armada’s most operationally demanding distribution centers in Romeoville, IL. The idea was that if Third Wave’s shared autonomy can perform in a legacy site, it can perform anywhere in the Armada network.
In January 2024, Armada Supply Chain Solutions, a leader in modern supply chain orchestration, partnered with Third Wave Automation to launch a one-year autonomous forklift pilot at one of Armada’s most operationally demanding distribution centers
in Romeoville, IL. The idea was that if Third Wave’s shared autonomy can perform in a legacy site, it can perform anywhere in the Armada network.
In January 2024, Armada Supply Chain Solutions, a leader in modern supply chain orchestration, partnered with Third Wave Automation to launch a one-year autonomous forklift pilot at one of Armada’s most operationally demanding distribution centers in Romeoville, IL. The idea was that if Third Wave’s shared autonomy can perform in a legacy site, it can perform anywhere in the Armada network.
In January 2024, Armada Supply Chain Solutions, a leader in modern supply chain orchestration, partnered with Third Wave Automation to launch a one-year autonomous forklift pilot at one of Armada’s most operationally demanding distribution centers in Romeoville, IL. The idea was that if Third Wave’s shared autonomy can perform in a legacy site, it can perform anywhere in the Armada network.
The program deployed four Third Wave Reach trucks integrated with Armada’s Warehouse Management System (WMS), with two clear objectives: prove autonomous forklift capability for product putaway in a real foodservice production environment and validate a deployment model that could scale across the Armada network without disrupting the operators and customers who depend on it. The pilot officially went live in Q4 2024 and has been extended through 2026.
The program deployed four Third Wave Reach trucks integrated with Armada’s Warehouse Management System (WMS), with two clear objectives: prove autonomous forklift capability for product putaway in a real foodservice production environment and validate a deployment model that could scale across the Armada network without disrupting the operators and customers who depend on it. The pilot officially went live in Q4 2024 and has been extended through 2026.
The program deployed four Third Wave Reach trucks integrated with Armada’s Warehouse Management System (WMS), with two clear objectives: prove autonomous forklift capability for product putaway in a real foodservice production environment and validate a deployment model that could scale across the Armada network without disrupting the operators and customers who depend on it. The pilot officially went live in Q4 2024 and has been extended through 2026.
“When we look at rolling out new technology in our distribution centers, our top priorities are safety, reliability, and efficiency. What really stood out about Third Wave was their shared autonomy model. It lets us automate parts of our operation without having to make infrastructure changes. That’s a big win. At the end of the day, improving safety makes this a better place for our teammates to work. And when you add in near-perfect inventory accuracy and fewer damages, it helps us lower costs. Most importantly, it helps make sure our customers get what they need, when they need it.”
“When we look at rolling out new technology in our distribution centers, our top priorities are safety, reliability, and efficiency. What really stood out about Third Wave was their shared autonomy model. It lets us automate parts of our operation without having to make infrastructure changes. That’s a big win. At the end of the day, improving safety makes this a better place for our teammates to work. And when you add in near-perfect inventory accuracy and fewer damages, it helps us lower costs. Most importantly, it helps make sure our customers get what they need, when they need it.”
“When we look at rolling out new technology in our distribution centers, our top priorities are safety, reliability, and efficiency. What really stood out about Third Wave was their shared autonomy model. It lets us automate parts of our operation without having to make infrastructure changes. That’s a big win. At the end of the day, improving safety makes this a better place for our teammates to work. And when you add in near-perfect inventory accuracy and fewer damages, it helps us lower costs. Most importantly, it helps make sure our customers get what they need, when they need it.”
Rick Rover
Rick Rover
Chief Operating Officer, Armada Supply Chain Solutions
Chief Operating Officer, Armada Supply Chain Solutions
Chief Operating Officer, Armada Supply Chain Solutions
The Challenge
The Challenge
The Challenge
A high-performing legacy site, never designed for automation
A high-performing legacy site, never designed for automation
A high-performing legacy site, never designed for automation
Romeoville is not a test site. It is a live, high-volume Armada distribution center that has been running foodservice operations since the late 1990s. The facility grew organically into adjacent space within the same building, with the two halves connected through a single doorway.
It was never designed with automation in mind. That is exactly why Armada selected this location to pilot the program.
Romeoville is not a test site. It is a live, high-volume Armada distribution center that has been running foodservice operations since the late 1990s. The facility grew organically into adjacent space within the same building, with the two halves connected through a single doorway. It was never designed with automation in mind. That is exactly why Armada selected this location to pilot the program.
Romeoville is not a test site. It is a live, high-volume Armada distribution center that has been running foodservice operations since the late 1990s. The facility grew organically into adjacent space within the same building, with the two halves connected through a single doorway.
It was never designed with automation in mind. That is exactly why Armada selected this location to pilot the program.
Romeoville is not a test site. It is a live, high-volume Armada distribution center that has been running foodservice operations since the late 1990s. The facility grew organically into adjacent space within the same building, with the two halves connected through a single doorway.
It was never designed with automation in mind. That is exactly why Armada selected this location
to pilot the program.
Tall Payloads (as tall as 103”)
Tall Payloads (as tall as 103”)
Tall Payloads (as tall as 103”)
Palletized payloads taller than 64 inches complicated perception, navigation, and autonomous placement decisions.
Palletized payloads taller than 64 inches complicated perception, navigation, and autonomous placement decisions.
Palletized payloads taller than 64 inches complicated perception, navigation, and autonomous placement decisions.
Push-Back Racking
Push-Back Racking
Push-Back Racking
Multi-deep push-back rack systems are not natively supported by most autonomous platforms, requiring specialized handling from Third Wave Automation.
Multi-deep push-back rack systems are not natively supported by most autonomous platforms, requiring specialized handling from Third Wave Automation.
Multi-deep push-back rack systems are not natively supported by most autonomous platforms, requiring specialized handling from Third Wave Automation.
WMS Integration Complexity
WMS Integration Complexity
WMS Integration Complexity
Integrating Third Wave’s API with Armada’s WMS required engineering changes on both sides and careful stakeholder coordination.
Integrating Third Wave’s API with Armada’s WMS required engineering changes on both sides and careful stakeholder coordination.
Integrating Third Wave’s API with Armada’s WMS required engineering changes on both sides and careful stakeholder coordination.
Legacy Site Layout
Legacy Site Layout
Legacy Site Layout
A 12-foot breezeway serves as the single travel lane connecting both sides of the warehouse, requiring trucks to sequence movements rather than pass simultaneously.
A 12-foot breezeway serves as the single travel lane connecting both sides of the warehouse, requiring trucks to sequence movements rather than pass simultaneously.
A 12-foot breezeway serves as the single travel lane connecting both sides of the warehouse, requiring trucks to sequence movements rather than pass simultaneously.
The Solution
The Solution
The Solution
Shared Autonomy: The Differentiator That Made It Work
Shared Autonomy: The Differentiator That Made It Work
Shared Autonomy: The Differentiator That Made It Work
At the heart of Third Wave’s approach is its Shared Autonomy platform, which allows remote operators to assist trucks through situations outside standard autonomous parameters. At Romeoville, push-back racking and taller payloads (103”) were the two conditions that required it most. In both cases, the platform routes the move to a remote operator before the situation arises, keeping operations running without interruption. Rather than treating these constraints as failures, Third Wave used each one as a data point, continuously refining autonomy rates throughout the pilot.
At the heart of Third Wave’s approach is its Shared Autonomy platform, which allows remote operators to assist trucks through situations outside standard autonomous parameters. At Romeoville, push-back racking and taller payloads (103”) were the two conditions that required it most. In both cases, the platform routes the move to a remote operator before the situation arises, keeping operations running without interruption. Rather than treating these constraints as failures, Third Wave used each one as a data point, continuously refining autonomy rates throughout the pilot.
At the heart of Third Wave’s approach is its Shared Autonomy platform, which allows remote operators to assist trucks through situations outside standard autonomous parameters. At Romeoville, push-back racking and taller payloads (103”) were the two conditions that required it most. In both cases, the platform routes the move to a remote operator before the situation arises, keeping operations running without interruption. Rather than treating these constraints as failures, Third Wave used each one as a data point, continuously refining autonomy rates throughout the pilot.
Third Wave’s integration with Armada’s WMS introduced directed putaway, meaning every pallet is placed precisely where the system specifies rather than at the nearest available location chosen by an operator. This by-design accuracy contributed to 99.94% inventory accuracy across all pallets handled by the Third Wave fleet, and Armada estimates it generates approximately $7,500 in monthly savings through the near-elimination of misplaced and lost pallet recovery costs. Combined with other efficiencies, Armada estimates a total savings of $18,000 per month.
Third Wave’s integration with Armada’s WMS introduced directed putaway, meaning every pallet is placed precisely where the system specifies rather than at the nearest available location chosen by an operator. This by-design accuracy contributed to 99.94% inventory accuracy across all pallets handled by the Third Wave fleet, and Armada estimates it generates approximately $7,500 in monthly savings through the near-elimination of misplaced and lost pallet recovery costs. Combined with other efficiencies, Armada estimates a total savings of $18,000 per month.
Third Wave’s integration with Armada’s WMS introduced directed putaway, meaning every pallet is placed precisely where the system specifies rather than at the nearest available location chosen by an operator. This by-design accuracy contributed to 99.94% inventory accuracy across all pallets handled by the Third Wave fleet, and Armada estimates it generates approximately $7,500 in monthly savings through the near-elimination of misplaced and lost pallet recovery costs. Combined with other efficiencies, Armada estimates a total savings of $18,000 per month.
What made the difference
What made the difference
What made the difference
Remote Exception Handling: operators assist trucks through situations outside standard autonomous parameters without stopping production.
Remote Exception Handling: operators assist trucks through situations outside standard autonomous parameters without stopping production.
Travel Reservations: trucks reserve sections of a shared travel path before entering, reducing bottlenecks through the single-lane breezeway.
Travel Reservations: trucks reserve sections of a shared travel path before entering, reducing bottlenecks through the single-lane breezeway.
WMS-Directed Putaway: every pallet is placed precisely where the system specifies rather than at the nearest available location chosen by an operator.
WMS-Directed Putaway: every pallet is placed precisely where the system specifies rather than at the nearest available location chosen by an operator.
Continuous improvement: each exception used as a data point, continuously refining autonomy rates throughout the pilot.
Continuous improvement: each exception used as a data point, continuously refining autonomy rates throughout the pilot.
No infrastructure changes: the results gave Armada a tested, repeatable model without a teardown, a rebuild, or a change in headcount.
No infrastructure changes: the results gave Armada a tested, repeatable model without a teardown, a rebuild, or a change in headcount.
Rapid layout updates: each change implemented with minimal disruption, with roadmap updates completed within hours.
Rapid layout updates: each change implemented with minimal disruption, with roadmap updates completed within hours.
Deployment Timeline
Deployment Timeline
Deployment Timeline
From partnership to production in under a year
From partnership to production in under a year
From partnership to production in under a year
July 2024
July 2024
July 2024
Trucks Arrive On-Site
Trucks Arrive On-Site
Trucks Arrive On-Site
Four Third Wave Reach trucks deployed. Third Wave begins operating trucks in production for four months of site learning.
Four Third Wave Reach trucks deployed. Third Wave begins operating trucks in production for four months of site learning.
Four Third Wave Reach trucks deployed. Third Wave begins operating trucks in production for four months of site learning.
October 2024
October 2024
October 2024
WMS Integration Complete
WMS Integration Complete
WMS Integration Complete
Blue Yonder integration finalized following UAT completion, enabling directed putaway and precise inventory tracking across the Third Wave fleet.
Blue Yonder integration finalized following UAT completion, enabling directed putaway and precise inventory tracking across the Third Wave fleet.
Blue Yonder integration finalized following UAT completion, enabling directed putaway and precise inventory tracking across the Third Wave fleet.
November 2024
November 2024
November 2024
Pilot Goes Live
Pilot Goes Live
Pilot Goes Live
Official pilot launch. Armada and Third Wave Automation begin co-managed operations.
Official pilot launch. Armada and Third Wave Automation begin co-managed operations.
Official pilot launch. Armada and Third Wave Automation begin co-managed operations.
December 2024
December 2024
December 2024
Fleet Handed Off to Armada
Fleet Handed Off to Armada
Fleet Handed Off to Armada
Armada operators take full ownership. Third Wave provides 1-800 support and certifies an on-site Armada trainer.
Armada operators take full ownership. Third Wave provides 1-800 support and certifies an on-site Armada trainer.
Armada operators take full ownership. Third Wave provides 1-800 support and certifies an on-site Armada trainer.
January 2026
January 2026
January 2026
Pilot Successfully Concludes
Pilot Successfully Concludes
Pilot Successfully Concludes
Romeoville site converts into a commercial deployment, and network-wide expansion planning begins.
Romeoville site converts into a commercial deployment, and network-wide expansion planning begins.
Romeoville site converts into a commercial deployment, and network-wide expansion planning begins.
Results
Results
Results
Measurable outcomes across safety, accuracy, and throughput
Measurable outcomes across safety, accuracy, and throughput
Measurable outcomes across safety, accuracy, and throughput
Across 12 months of live production, the Third Wave fleet delivered measurable results at a site that was never optimized for automation.
Across 12 months of live production, the Third Wave fleet delivered measurable results at a site that was never optimized for automation.
Across 12 months of live production, the Third Wave fleet delivered measurable results at a site that was never optimized for automation.
Metric
Metric
Result
Result
Context
Context
Total Pallets Moved
Total Pallets Moved
Total Pallets Moved
25,863
25,863
25,863
Moved across 12 months of live production at the Romeoville facility.
Moved across 12 months of live production at the Romeoville facility.
Moved across 12 months of live production at the Romeoville facility.
Avg. In-Spec Moves / Truck / Hour
Avg. In-Spec Moves / Truck / Hour
Avg. In-Spec Moves / Truck / Hour
10.7
10.7
10.7
Exceeded the revised contract target of 8. The median move distance was 185 meters, with some moves exceeding 500 meters.
Exceeded the revised contract target of 8. The median move distance was 185 meters, with some moves exceeding 500 meters.
Exceeded the revised contract target of 8. The median move distance was 185 meters, with some moves exceeding 500 meters.
Time in Full Autonomy
Time in Full Autonomy
Time in Full Autonomy
68%
68%
68%
Achieved at a site with push-back racking and palletized payloads as tall as 103 inches, both of which require operator assistance on individual moves.
Achieved at a site with push-back racking and palletized payloads as tall as 103 inches, both of which require operator assistance on individual moves.
Achieved at a site with push-back racking and palletized payloads as tall as 103 inches, both of which require operator assistance on individual moves.
Inventory Accuracy
Inventory Accuracy
Inventory Accuracy
99.94%
99.94%
99.94%
For all pallets handled by the Third Wave fleet, driven by WMS-directed putaway that eliminates misplacement.
For all pallets handled by the Third Wave fleet, driven by WMS-directed putaway that eliminates misplacement.
For all pallets handled by the Third Wave fleet, driven by WMS-directed putaway that eliminates misplacement.
Truck Availability
Truck Availability
Truck Availability
90.4%
90.4%
90.4%
Maintained across 3,849 production hours over the full pilot period.
Maintained across 3,849 production hours over the full pilot period.
Maintained across 3,849 production hours over the full pilot period.
Safety Incidents
Safety Incidents
Safety Incidents
0
0
0
Zero incidents, zero injuries, zero racking damage and infrastructure damage across all 3,849 production hours.
Zero incidents, zero injuries, zero racking damage and infrastructure damage across all 3,849 production hours.
Zero incidents, zero injuries, zero racking damage and infrastructure damage across all 3,849 production hours.
$18,000
$18,000
$18,000
Estimated Total Monthly Savings
Estimated Total Monthly Savings
Estimated Total Monthly Savings
Derived from time savings associated with autonomous operations.
Derived from time savings associated with autonomous operations.
Derived from time savings associated with autonomous operations.
In Their Own Words
In Their Own Words
In Their Own Words
Operational perspective
Operational perspective
Operational perspective
“This pilot demonstrated real operational value, higher accuracy, predictable performance, and meaningful labor leverage. We knew it was going to be a challenge to implement this technology in a brownfield site, but we were pleased at the results of running almost 70% autonomously in a legacy building. Third Wave was very responsive to our requirements, and we are confident that when implemented in a greenfield environment, we could run 90%+ autonomously using Third Wave Automation. We now have a clear roadmap for expanding this technology across the Armada network.”
“This pilot demonstrated real operational value, higher accuracy, predictable performance, and meaningful labor leverage. We knew it was going to be a challenge to implement this technology in a brownfield site, but we were pleased at the results of running almost 70% autonomously in a legacy building. Third Wave was very responsive to our requirements, and we are confident that when implemented in a greenfield environment, we could run 90%+ autonomously using Third Wave Automation. We now have a clear roadmap for expanding this technology across the Armada network.”
“This pilot demonstrated real operational value, higher accuracy, predictable performance, and meaningful labor leverage. We knew it was going to be a challenge to implement this technology in a brownfield site, but we were pleased at the results of running almost 70% autonomously in a legacy building. Third Wave was very responsive to our requirements, and we are confident that when implemented in a greenfield environment, we could run 90%+ autonomously using Third Wave Automation. We now have a clear roadmap for expanding this technology across the Armada network.”
Kris Jensen
Kris Jensen
Vice President of Warehouse Operations, Armada Supply Chain Solutions
Vice President of Warehouse Operations, Armada Supply Chain Solutions
Ready to Get Started?
Ready to Get Started?
Ready to Get Started?
See what Shared Autonomy can do for your operation
See what Shared Autonomy can do for your operation
See what Shared Autonomy can do for your operation
The results at Romeoville are repeatable. Find out how Third Wave's Shared Autonomy platform can deliver the same accuracy, safety, and efficiency across your network.
The results at Romeoville are repeatable. Find out how Third Wave's Shared Autonomy platform can deliver the same accuracy, safety, and efficiency across your network.
The results at Romeoville are repeatable. Find out how Third Wave's Shared Autonomy platform can deliver the same accuracy, safety, and efficiency across your network.
Stay up-to-date with
Third Wave Automation
We improve our products and advertising by using Microsoft Clarity to see how you use our website. By using our site, you agree that we and Microsoft can collect and use this data. Our privacy statement has more details.
Stay up-to-date with
Third Wave Automation
We improve our products and advertising by using Microsoft Clarity to see how you use our website. By using our site, you agree that we and Microsoft can collect and use this data. Our privacy statement has more details.
Stay up-to-date with
Third Wave Automation
We improve our products and advertising by using Microsoft Clarity to see how you use our website. By using our site, you agree that we and Microsoft can collect and use this data. Our privacy statement has more details.