Amazon Logistics (Middle Mile)
Optimized PLC logic for package sorters, tightening gaps to increase throughput by ~15–20%.
$6–8M annual savings
About
The competitive technologist.
A convergence of the hands-on maker who fabricates a single perfect part and the systems architect who moves a million units with zero defects.
Trusted by
From guaranteeing performance to guaranteeing scale
In 2005, I co-founded Predator Cycling with a simple premise: a bicycle should be a biomechanical extension of the athlete. That "Riders First" philosophy forced us to abandon traditional manufacturing cycles in favor of parametric design and simulation. We didn't just build bikes; we built data loops.
That obsession produced the 5D Manufacturing Methodology — a cyclical framework (Design, Develop, Data Log, Drive, Deliver) that enabled Olympic-caliber equipment like "The Major" cockpit and the RF20 road frame.
Recently, those boutique principles moved to global logistics. At Amazon, I re-architected sorter logic to increase package throughput by nearly 20%. At Walmart, I'm pioneering multi-agent orchestration and autonomous robotics for cold-chain distribution.
The 5D Methodology
01
Design
Parametric models driven by live constraints and customer data.
02
Develop
Virtual prototyping through CFD, FEA, and digital twin validation.
03
Data Log
Trace every manufacturing variable into a digital birth certificate.
04
Drive
Close the gap between simulation and shop-floor reality.
05
Deliver
Ship with traceable quality control and logistics feedback.
Engineering impact
Walmart Automation (Cold Chain)
Researching AMRs for refrigerated environments and implementing multi-agent orchestration to bridge WMS/WES silos.
Systemic reliability
The next frontier: industrial AI
We are moving beyond simple automation to intelligent optimization. My work with AyoWork explores the manufacturing metaverse — connecting unlinked datasets to create a just-in-time production loop that reacts to market interest before an order is placed.
Explore the AyoWork case study →