How ODW Logistics avoided $1M in turnover costs with a more resilient, audit-ready workforce

A fragmented environment that failed to scale

For a third-party logistics company managing more than 2,000 associates, a gap in training records isn’t just an inconvenience, it’s a liability.

ODW Logistics is such a provider, offering warehousing, distribution, and transportation solutions for leading brands across a wide range of industries. Each of their 26 distribution centers serves multiple clients, all with their own compliance standards and certification requirements.

With hundreds of associates at each distribution center, the training tracking system struggled to keep up.

“We created job breakdown sheets and trained associates on the standardized work. They would physically sign the document, which we would scan into our shared drive, and upload into an Excel file,” said Continuous Improvement Manager Robert Darnell.

The approach was time-consuming and error-prone. Without a reliable picture of who was trained on what, day-to-day operations relied on tribal knowledge.

“We’d pair a new hire with someone who’s been here for five years, but that person wouldn’t document how they trained the new hire. There was no proof that training ever happened,” said Training and Development Specialist Jessica Gibson.

Lost documentation and lack of visibility left the team exposed during audits, jeopardized client service levels, and limited their ability to sustain growth.

Our training programs weren’t sustainable for the number of people we were bringing on and the services we were providing.

Cody Congdon

General Manager, ODW Logistics

A single source of truth that drives agility

ODW Logistics wanted to centralize and standardize training data, and they decided that AG5 was the best way to do it.

“We were looking for something that was clear, concise, easy to use, and thorough,” said General Manager Cody Congdon. “AG5 is a one-stop shop for all of our training needs.”

Another benefit was flexibility.

During implementation, the ODW team had weekly meetings with the AG5 developers and sales team to fine-tune what they wanted in the final product. Some of the things ODW Logistics wanted weren’t possible at the time, but AG5 made plans to address them in the future and have begun to work through the list.

“We really liked how they were able to meet us where we were,” Darnell said. “The dedication to serving us as a customer pushed them ahead of the pack.”

The ODW Logistics team consolidated their previously siloed training data into a single file, which the AG5 team uploaded to create a single source of truth for all skills and training records. Instantly, ODW Logistics gained a real-time view of qualifications across the company and can respond immediately to emerging needs.

In adopting AG5, ODW Logistics shifted the focus away from ineffective record-keeping to operational optimization.

 

A specialized matrix boosts cross-network visibility

Typical LMS systems are often too cumbersome for a fast-paced warehouse. AG5’s specialized skills matrix enables a floor manager to discover qualified associates at any time.

“With AG5, we have the ability to put the right person in the right task at the snap of a finger,” Congdon said. “That direct input allows us to be efficient and help deliver our difference to the client without any risks of process gaps or integrity of the product being compromised.”

That labor sharing has become a strong competitive advantage. If a distribution center is at peak capacity, leaders can identify and request cross-trained associates from across the network to cover shifts.

The skills matrix has also raised training quality, making it easier for ODW Logistics to identify and use subject matter experts rather than defaulting to seniority.

Reliability when it matters most

The true test of the skills matrix arrived during an operational nightmare for ODW Logistics.

One of the company’s warehouses supplies three different original equipment manufacturers (OEMs). When a force majeure forced the closure of that warehouse, they faced a crisis: a line shutdown.

“You do not want to be the reason that that line shuts down—line shutdowns are very, very expensive,” Congdon said.

ODW Logistics turned to AG5’s skills matrix to find employees who could get things running again.

“Although we had to shut down the warehouse for a shift, we were able to lean on the rest of our folks outside of that specific account who were cross-trained into our automotive account, and we were able to flex them over on off shifts,” Congdon said.

After bringing in those employees, ODW Logistics caught up within a day, avoiding a line shutdown that could have cost millions.

Data-driven operational planning

Another valuable benefit comes from the bench strength feature, which the team uses to identify weak spots and plan cross-training based on customer forecasts. This approach transforms labor planning from reactive to proactive.

Meanwhile, certification expiry tracking ensures associates aren’t deployed with lapsed credentials.

“I had a training lead whose Good Manufacturing Practice (GMP) certification was expiring. I got her into a recertification class ahead of a project I had scheduled for her. If I didn’t have AG5, I wouldn’t have seen that,” Darnell said.

A smoother pathway for employee development

Teams also use AG5 to compare an associate’s competency against a target site’s requirements, building a clear path to close gaps and boosting leadership opportunities. The platform also empowers associates, who have full visibility into their skills.

“We like to think of it as a resumé to the company,” Gibson said. “AG5 is a great example to use and say, ‘I know all of these skills, I am valuable to this company,’ and that leads to more promotions and interviews.”

Greater confidence through continuity

By replacing Excel sheets and paper documentation with a unified platform, ODW Logistics has cut training record uploads by 99%.

Before AG5, uploading training documents took anywhere from an hour to two days. With AG5, we’ve cut that down to about a minute.

Robert Darnell

Continuous Improvement Manager at ODW Logistics

As associates move between buildings and accounts, AG5 ensures they are certified on all required tasks before arrival, giving the team confidence that compliance is never in question. And when ODW Logistics needed to upload 7,000 safety documents, the AG5 team was there.

“My experience with the AG5 team has been extraordinary. They gave us project dates, tasks, and clear next steps to get this large volume of documentation into our one source of truth,” Gibson said.

Low turnover leads to $1M in cost savings

ODW Logistics has dropped below the 20% industry turnover standard, avoiding the need to hire 250 new associates. At $4,000 per onboarding, this improved retention translates to more than $1 million in total cost avoidance.

The impact on morale has been just as significant. Employee satisfaction scores have risen from around 80% to above 90% across the organization.

“When associates see management investing in their development, it takes them from feeling like just a number to knowing they have a plan. Seeing their eyes light up when they see their name on that screen—I don’t think you can put a price tag on that,” Darnell said.

Guaranteed audit-readiness and a path to ISO certification

Training records are now always current and ready for any audit. AG5 captures all training details in one place and integrates with ODW Logistics’ Quality Management System to ensure documentation always reflects the most current process revision.

Before AG5, there was a lot of scrambling before audits. With AG5, audit readiness is much easier. We have all the tools right at the click of a button.

Cody Congdon

General Manager at ODW Logistics

Since implementing AG5, ODW Logistics has passed every compliance audit. The platform’s documentation structure, training records, and sign-off trails were critical to obtaining their ISO 9001:2015 certification.

“AG5 has helped raise the confidence in our teams going into these audits that we are appropriately prepared and ready to deliver what is expected of us. Before, that was never something we could say with confidence,” Congdon said.

With the help of AG5, ODW Logistics has effectively closed the gap between operational catastrophe and the compliance-driven excellence their clients expect.