FORTE Develops a New Pick-by-Wave System with only 2 Touches per Carton when Cross-Docked

The Challenge
This Texas facility was a floor care leader and a recognized name in household appliances, but couldn’t keep up in their conventional warehouse with no automation.

Their manual operation struggled with efficiency and accuracy as workers built pallets using pick lists and hand labeled and cross-checked each carton.

The Solution
FORTE developed a new pick-by-wave system with an automated print and apply station. A new U-shaped induct conveyor moves the cartons through a scanner and down one of three divert lanes directly into a truck.

FORTE strategically developed the shipping layout to double as a receiving system.

Using the same equipment, product can be received and immediately palletized for storage.

An added advantage of the new design is easier cross-docking. Cartons being cross-docked simply remain on the conveyor through the print and apply station and divert for immediate shipment.

The Result
Accuracy was increased through the automatic print and apply. Lead times were reduced through cross-docking and batch picking. The number of touches per carton dropped from 7 to 2 if cross-docked and 7 to 4 if batch picked and shipped.

Picking by batch allows for synchronization with truck arrival, eliminating the need to stage pallets on the dock. Overall customer service levels increased.

“The project’s ROI met payback period requirements and had the added benefits of increased accuracies and heightened customer service levels.” Project Manager, Floor Care Leader