DC Retrofit

Retrofitting an existing system can bring new life to a Distribution Center.

The Challenge:

This Texas facility was a floor care leader and a recognized name in household appliances, but couldn't keep up in their conventional warehouse without warehouse automation. Their manual operation struggled with supply chain efficiency and accuracy as workers built pallets using pick lists and hand labeled and cross-checked each carton.

The Solution:

FORTE developed a new pick-by-wave system with an automated print and apply station. A new U-shaped induct conveyor moves the cartons through a scanner and down one of three divert lanes directly into a truck. FORTE strategically developed the shipping layout to double as a receiving system. Using the same material handling equipment, product can be received and immediately palletized for storage.

An added advantage of the new warehouse design is easier cross-docking. Cartons being cross-docked simply remain on the conveyor through the print and apply station and divert for immediate shipment.

The Result:

Only 2touches per carton if cross-docked

As a result of FORTE's new warehouse automation retrofits and conveyor system solutions, accuracy was increased through the automatic print and apply. Lead times were reduced through cross-docking and batch picking. The number of touches per carton dropped from 7 to 2 if cross-docked and 7 to 4 if batch picked and shipped. Picking by batch allows for synchronization with truck arrival, eliminating the need to stage pallets on the dock. Overall customer service levels increased.

Key Services Employed Strategic Development Facility Performance Analysis Automated Material Handling Systems