This family-owned business distributed personal care products to retailers from its 100,000 square foot warehouse. However, space was very tight and the operation required year-round offsite storage. Another issue was the change in operational requirements to support more and more orders for direct-to-store shipments rather than bulk shipments to the customer’s distribution center.
In order to support its business growth, the company selected Distribution Design to provide analysis and design services. The resulting design included an addition to the existing facility so the offsite storage could be just seasonal; new operational processes to support many small orders in partial-case quantities; a new layout with conveyor-supported picking; improved WMS functionality; a productivity improvement of about 25%; and an implementation methodology to support the migration to the new operation while continuing to provide daily shipments.