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Case Study: New Facility

Jean image

Features of the New
Distribution Center

- Static picking rack for slow movers. Picking rack was designed to support a second level of garment on hanger in the future.

- Carton flow rack for the picking of fast-moving seasonal items.

- A pick and pass conveyor system linking value-added services, slow-moving rack picking and fast-moving carton flow picking.

- A value-added system that enables efficient stickering and hanging of department store orders.

- In-line packing stations that allow for complete order processing and manifesting.

- A shipping sorter that facilitates pallet building of department store orders and export orders, as well as direct loading of UPS orders into a UPS truck.

- A pack and hold storage area which promotes improved monthly workload balancing.


Client Overview
  • A leader in the high-end denim industry had outgrown its original facility and relocated to a refurbished corporate headquarters that included a distribution center (DC).

Tompkins' Role

  • Designed the overall facility based on a five-year planning horizon. The design included strategic initiatives and a more effective value-added processing area.
  • Developed equipment costing and justification, including a return on investment calculation.
  • Implemented warehousing management system (WMS) requirements for the new facility, allowing for improved methods within the DC.
  • Supported the current WMS vendor in making modifications to support the new layout and improved operation.
  • Performed a detailed design of the new layout and established bid specification documents for material handling providers to bid on the project.
  • Managed the bidding process and selected a materials handling provider.
  • Coordinated the installation of the material handling equipment.
  • Managed the inventory transfer and start-up of the new operation.

The Solution

  • Developed a successful DC start-up undeterred by the aggressive schedule required to meet business needs.
  • Established an expandable system that mitigates operational downtime and risks associated with future modifications due to growth.
  • Created a DC design that allowed the company to reduce their DC workforce by 30% and increase their processing rates by more than 300%.

 

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