For a major appliance manufacturer’s facility, limited space and outdated processes were inhibiting their ability to reach growth objectives. Their 100% utilization of current storage space, overloaded order flow system, and long travel times for material retrieval were pushing up labor costs.
DAK designed and implemented an end-to-end solution including high-density storage (FIFO), a modern pallet flow system and a non-contact accumulation conveyor with constant pallet orientation and random pallet selection.
The facility gained a 30% increase in storage space using 14 deep bays in 58-foot flow lanes that optimized product retrieval and reduced manpower requirements. Newly implemented sensors allowed workers to pause the conveyor for random pallet picking. Finally, truck travel time dropped by 10%, reducing labor costs.