Fast Track Retrofit Project

Company Information

• Rapidly growing provider of out-sourced services for direct to consumer fulfillment
• Provides web-based front office and order fulfillment services for many multi-billion dollar clients
• Operates four facilities in the Louisville area
• Serves multiple clients and multiple missions out of each facility
  
  

Business Problem(s)

• Significant business growth and solid business development forced an assessment of holding capacity and processing volume for handling pending clients
• Peak season processing / accuracy needed to improve over previous year
  
  

TPG Challenge

• Revamp receive/store/pick/pack processes for better performance
• Recommend a configuration for significantly increased storage capacity
• Increase productivity by reducing order picker truck activity and reducing replenishment tasks
• Work with senior management to develop a solid business case
• Develop a solution and a plan that can be “Fast-tracked” in time for the next peak season
  

  
  

Results

• A retrofit design that included a 3 level mezzanine, an automated Receiving system, a tote routing system for inbound and outbound, and advanced “middleware” planning software integrated with their WMS and control systems
• Receiving planning and control integrated with an innovative slotting program – 42% reduction in direct hrs
• Achieved 30% productivity improvement and 100% improvement in mission capacity