A distributor of retail products for convenience stores, smoke shops, truck stops, neighborhood markets, and other retailers in Washington, Oregon, Idaho, California, Nevada, Utah, and Arizona.
The client needed a quicker and more efficient way to manage their inventory, picking, route stop sequence sortation, and loading which were all heavily reliant on manual processes. For example, their existing system required palletization, manual transfer, and depalletization in the truck.
KPI implemented their Opto Software in a completely turnkey 350,000 sq. ft. distribution center featuring a high-speed sliding shoe shorter, four pick modules, and over a mile of conveyor. The new system handles 5,000+ SKUs and 40 cartons per minute.
Orders are now picked from each of the modules and released to a central merge where they are batch released into a 16-lane shoe sorter for route stop sequence sortation and buffering.
Once the dock is ready for products held in the buffer lanes, they are released to the dock and sorted to the correct door. Products are then fluid loaded directly into the truck. Opto Software is the key for fast and efficient order management.
- Route stop sequence sortation
- WCS with the ability to pick multiple stops simultaneously from different areas and re-sequence them
- Completely suspended shipping dock area conveyor system
- Ability to react in an efficient manner to dramatically increasing volumes