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A new state-of-the art distribution center
To deliver a best-in-class customer experience, the company built a modern 275,000-square-foot distribution center adjoining its manufacturing facility.
Parallel handling systems
Because shipping cycles, order volumes and packaging requirements vary by customer type, the facility supports two parallel material handling systems:
- An each-pick system for diverse order profiles
- A case picking system dedicated to retail distribution
Mixed use each and case picking system
The company ships to retail stores, distributors, ecommerce customers and distribution centers. This meant that its picking system for those orders needed flexibility and speed.
The picking process
Orders are downloaded from the enterprise system and assigned to picking zones. The system determines the appropriate carton size and prints it on the shipping label.
Pickers place cartons on the conveyor, apply labels and begin picking in the most efficient zone for fast work and minimal transport time on the conveyor system. A center-line conveyor, known as the express lane, transports cartons from zone to zone. It sits between picking lanes, which are placed in easy ergonomic reach.
Once an order is fully picked, it moves to scales and taping systems without delay.
Integrated qualify control
Redundant checks—based on weight and quantity—help ensure accuracy. Orders outside tolerance are diverted for manual verification. Once approved, cartons are sealed and sent to shipping. The warehouse management system (WMS) confirms shipment and triggers automated customer notifications.
The shipping system
Picking, quality checks and sealing occur on a second level, while shipping sortation is positioned above dock doors on a ceiling-supported platform. As packages move through the system:
- Parcel shipments are routed to flexible conveyors feeding trailers
- LTL shipments bypass parcel areas and move directly to carrier doors
- Shipping destinations can be dynamically adjusted as needed
The system enables faster fulfillment and is designed for future scalability.
The case pick retail pick module
A multilevel, rack-supported pick module enables efficient full-case picking and palletizing for retail distribution centers.
Sortation and palletizing
Orders are released to the picking system with integrated SKU, site and quantity data.
When multiple orders require the same SKU, items are picked in bulk and sent to a sortation loop. The loop directs cartons to the correct palletizing lanes, where pallets are built and stretch-wrapped for shipment. That loop diverts specific cartons to the proper destinations for palletizing. Cartons travel on the loop until all orders are filled. As cartons fill the palletizing lines, pallets are built and stretch-wrapped for shipping.
Redundant checks ensure the correct quantities and SKUs are shipped for every order, reinforcing the company's commitment to accuracy and customer satisfaction.
The results: faster, better order fulfillment for superior customer service
The company achieved its goals, all centered on delivering a customer experience that reflects the quality of its products:
Improved accuracy and quality
The system simplified order processing and built-in integrated error checking that helps detect and avoid errors and returns.
Improved employee safety and ergonomics.
The system minimizes employee bending, stretching and manual handling. Forklift-pedestrian interactions were reduced.
Faster shipping and fulfillment
By eliminating bottlenecks, simplifying picking processes and a focus on picking efficiency, throughput was increased significantly.
Reduced manual handling with minimal touchpoints
The system reduces the number of order interactions required to fulfill more efficiently. Pickers have more and faster information to rapidly fulfill orders.
Scalability and future expansion are baked in
Scalability for future growth with expansion-ready infrastructure were installed with the system. When it's time to expand, the system can easily be adapted to changing customer preferences, growth and market conditions.
The company can now process orders faster than ever. With strategically positioned inventory and improved data visibility, it is well positioned for continued growth.