Complex Cartonization and a Santa Claus with a Six Sigma Edge

When you think of warehouse automation and Santa Claus, you probably don’t imagine them having much in common. But after my conversation with Ken Ray, WMS Systems Engineer at Cooper Lighting Solutions — and a professional Santa Claus — I learned that both roles are powered by a unique combination of precision, creativity, and heart.

Ken Ray joined me on the latest episode of Warehouse Automation Matters to share his expertise on complex cartonization, a process that has transformed Cooper Lighting’s operations. But our conversation began on a more whimsical note: Ray’s journey to becoming a licensed Santa Claus. This unexpected side hustle, rooted in his warmth and knack for bringing joy, serves as a perfect counterbalance to his engineering knowledge.

From Ken Kringle to Complex Cartonization

Ray’s Santa journey started in 2018 when he and his wife decided to start a chestnut farm and look like Mr. and Mrs. Claus to sell chestnuts. Ken embraced his alter ego, Ken Kringle — Santa's lesser-known brother — and soon found himself enchanting crowds in unlikely places, like the grocery aisle of a local Walmart. A touching interaction with a child changed everything for Ray, prompting him to attend Santa Claus school and earn his certification as a professional Santa.

“It didn’t seek me out; it called me,” Ray shared during our conversation. That same passion for making people’s lives a little brighter also fuels his dedication to revolutionizing warehouse operations.

What Is Complex Cartonization?

While Santa has the advantage of a magic sleigh to carry perfectly wrapped presents, real-world warehouses face more logistical challenges. That’s where complex cartonization comes in. In simplest terms, it’s the process of determining the most efficient way to pack and ship products to ensure they arrive intact and in the smallest possible box. But, as Ray explained, the process is far from simple.

“Cartonization is about taking a look at whatever a customer ordered and figuring out how to ship it in the smallest carton that will get it there undamaged,” Ray explained. At Cooper Lighting, this was no small feat, as they deal with fragile lighting components that require special handling. Their old system, which relied on “fluid cartonization,” was only accurate about 64–66% of the time, leading to wasted time and materials.

The solution? A data-driven approach that uses advanced algorithms to model and select the optimal carton size. This system, combined with automation tools like Locus Robotics and PackSize, transformed Cooper Lighting’s packing process.

Warehouse Automation in Action

Ray’s technical expertise shone as he described how Cooper Lighting overhauled their warehouse operations. By integrating complex cartonization into their warehouse management system (WMS), they eliminated unnecessary steps in the packing process. Products are now packed directly into their final shipping cartons at the point of picking, significantly reducing touchpoints and streamlining operations.

Before implementing this system, Ray said, “We had around 32 steps, 28 of which were non-value-added steps.” The new approach not only saved time but also improved customer satisfaction by reducing damages and speeding up delivery times.

Automation plays a crucial role in this transformation. Locus Robotics handles the heavy lifting, literally, while the PackSize machine produces custom-sized boxes on demand. Together, these tools ensure that cartons are sized precisely for the products they carry, reducing waste and shipping costs.

The Human Element Behind the Data

While technology is essential to Cooper Lighting’s success, Ray stressed that data quality is the linchpin of any cartonization system. “Garbage in, garbage out,” he reminded me. Ensuring accurate product dimensions and weights requires meticulous attention to detail. Early in the process, Cooper Lighting even hired a dedicated team member to verify product data.

Ray also highlighted the sustainability benefits of their cartonization solution. By minimizing the use of bubble wrap and reducing excess packaging, the company aligns with its parent company Signify’s goal of carbon neutrality. As Ray put it, “It’s less impactful on the environment, and by using cartons that fit the product better, we also save on shipping costs and fuel.”

Santa’s Lessons for Warehousing

What makes Ray’s story so fascinating is how his roles as Santa and WMS Systems Engineer intersect. As Santa, he spreads joy with every interaction, ensuring no detail is overlooked in creating magical moments. Similarly, his work in warehouse automation involves making every process more efficient and precise, ensuring that the end customer — whether they’re unboxing a Cooper Lighting product or unwrapping a holiday gift — has a positive experience.

When asked about the advice he’d give to companies hesitant to invest in complex cartonization, Ray’s response was simple: “Just do it. There’s really no reason not to do it unless you don’t have the scale to support it.” His enthusiasm reflects a belief that automation isn’t just about cutting costs — it’s about creating a system that works better for everyone involved, from warehouse workers to end consumers.

A Glimpse into the Future

Ray also shared his perspective on the future of warehouse automation. With customer expectations for fast, flawless delivery continuing to rise, automation will be essential for companies looking to stay competitive. “The companies that jump on the automation bandwagon are going to be the ones that are here in the future,” Ray said.

As someone who has seen executives laugh at the idea of robots in a warehouse, Ray takes pride in proving skeptics wrong. Cooper Lighting’s success demonstrates that with the right combination of technology and human ingenuity, warehouses can deliver not just products but also exceptional experiences.

Why Listen to This Episode?

Whether you’re a logistics professional or simply curious about how your online orders arrive so efficiently, this episode of Warehouse Automation Matters offers a behind-the-scenes look at the innovations shaping the industry. And if you’ve ever wondered how someone becomes both a Six Sigma Black Belt and a professional Santa Claus, Ken Ray’s story will inspire and delight you.

Don’t miss the full conversation, where we dive even deeper into the technical details of cartonization, the role of automation, and Ray’s plans for spreading holiday cheer as Ken Kringle.