White's Horizontal Carousel Increases Productivity by 66%
White's Horizontal Carousel Increases Productivity by 66%
Challenge
Challenge
A leading medical device manufacturer and distributor that ships to over 35,000 locations in the U.S. alone wanted an inventory control solution that improved picking accuracy for their 11 million items that shipped each year. Six associates were needed to manually fill 1,500 orders per day. Since the distribution center operates 24/7, this required a lot of labor hours. This process also involved high travel vs. picking time and it was difficult to manage order accuracy and inventory control. These items resulted in restricted throughput, limited efficiency, and picking errors.
Solution
Solution
White Intelligent Storage horizontal carousels are designed to quickly and ergonomically deliver items to the operator. Horizontal carousels were installed, allowing for the storage of over 16,000 SKU’s and 850,000 items. The carousels were designed in pods so labor capacity is optimized.
The operator initiates picking with the use of a hand held RF transmitter. The carousels position themselves and a lightree indicates the location and quantity of the first SKU to be picked. Inventory and supply tracking software was also implemented so picks can be scanned to check the SKU numbers against the order for greater accuracy and efficiencies.
Results
Results
Four horizontal carousels were installed to dramatically increase throughput and order accuracy. The horizontal carousels significantly decreased picking time for associates, meaning they could pick more orders in less time. Associates no longer have to walk back and forth to get supplies to fulfill orders increasing pick rates.
The horizontal carousels have significantly increased order fulfillment productivity through decreased picking time, increased order accuracy, and inventory control. Productivity increased 66%, using only two operators rather than six while increasing the volume of same-day shipments, order accuracy, and inventory control. Installing the carousel system provided labor efficiency, plus a return on investment (ROI) in less than 18 months. The White horizontal carousel system has improved efficiencies and positioned this distribution center for growth while generating greater customer satisfaction.