DC Facility Concept, Detailed Design, and  Specification

Company Information
Walt Disney World Co. in Orlando includes a distribution center for all merchandise in Walt Disney World Parks and Resorts, including Magic Kingdom, Epcot, MGM Studios, and Animal Kingdom. The distribution center includes a huge variety of products: Variation in activity, product life cycle, cube, order frequency, volume, and profitability. It comprises of 25,000 SKUs active, but the DC handles a total 50,000 SKUs.

Business Problem

• DC processes upgrade to facilitate current & future supply chain initiatives for service improvement and inventory reduction initiatives.
• Getting to appropriate level of inventory throughout the pipeline depended upon DC effectiveness

TPG Challenge

• Develop the conceptual and detailed design for processes and equipment for the warehouse and distribution center operation.
• Provide phased transition plan with minimal disruption to 24 hour per day operation

Results

• An innovative DC design that will increase throughput and productivity, allow supply chain visibility, and improve accuracy
• Projected ROI exceeding target
• Customer service vision that emerged from the project exceeded expectations