Top Hat Engineering
Transforming Warehouse Operations through Intelligent Automation

Top Hat Engineering is a service-disabled, veteran-owned small business that elevates warehouse optimization through its comprehensive software suite, Clarity. The platform integrates five machine learning-powered modules to optimize processes and increase throughput across all aspects of warehouse operations.

Across the industry, supervisors and managers often juggle multiple applications to monitor basic operational metrics. This constant switching between fragmented data consumes time, reduces visibility and makes it harder to obtain a real-time view of warehouse operations.

Clarity addresses these challenges by aggregating all operational metrics in one unified interface. Supervisors no longer need to manually extract and organize information. The platform analyzes operational inputs and recommends decisions on behalf of supervisors, who can simply review and approve them. This method transforms traditional warehouse management into an intelligent and adaptive system that reduces manual effort and enhances operational efficiency.

“We built Clarity from the operator’s point of view, because we’ve been in their shoes,” says Brennan Jackson, VP, sales & marketing.

With many team members having worked in the same operational roles as their customers, Top Hat Engineering brings firsthand understanding of warehouse challenges. This insider perspective shapes every solution they design. They are driven by a genuine intent to make a meaningful difference for each customer rather than meeting sales quotas.

A Data-Led Approach to Operational Excellence

Each of Clarity’s five modules is designed to address a critical area of warehouse performance.

Clear Flow orchestrates the flow of tasks and orders to balance workloads and ensure operations move seamlessly. Synchronizing robotics, conveyors and automation systems, Clear Gear maintains the continuous movement of goods and eliminates downtime. While machines stay coordinated, people stay empowered with Clear Team tracking workforce utilization and guiding supervisors with real-time information on performance and productivity. Clear Slot delivers dynamic inventory optimization. It uses heat map visualizations to identify the most efficient product placements and generates automated slotting recommendations based on velocity and pick patterns. Clear Pick introduces guided picking workflows that adapt to any environment, whether using wearables, handheld devices, lights, or voice systems. It provides optimized routes, real-time feedback, and quality control checks that reduce errors by up to 95 percent.

Out of these modules, Clear Flow, Clear Team and Clear Slot are cloud-based SaaS offerings that enables seamless access and management across locations. Clear Pick and Clear Gear are deployed on-premises to address latency requirements and ensure uninterrupted decision-making on-site, where even milliseconds can impact operational performance.

We built Clarity from the operator’s point of view, because we’ve been in their shoes.

To maximize the value of these modules, Top Hat Engineering follows a standardized procedure.

The process begins by conducting an on-site assessment to understand the client's operational challenges and daily pain points. Based on this, the team identifies which of the five Clarity modules will provide the most value.

Implementation is carried out in a modular, phased manner, beginning with the modules that address the customer’s most pressing challenges. This allows teams to adapt to the new system gradually. Over the following three months, the remaining modules are also integrated.

After the phased rollout, the system is scaled into the full network.

The team remains actively involved through on-site training and performance monitoring after deployment. This end-to-end involvement reflects the company’s core belief that ‘when the customer succeeds, we also do.’

A case in point is a pilot program for a Fortune 50 customer where the client’s outdated processing operation was overhauled. An automated inbound sortation system was rolled out, resulting in a dramatic increase in throughput. Units processed per hour improved from approximately 170 to 665, reflecting a 285 percent increase.

In another engagement, process redesign and optimization tools delivered a 75 percent reduction in labor hours for the client. Operations that previously required 80 labor hours were streamlined to just 22, providing an immediate return on investment.

Through long-term partnerships grounded in real-world experience, Top Hat Engineering remains the go-to partner for warehouses seeking tangible operational improvements.