The DC receives product from ATG manufacturing plants in the U.S. and elsewhere in the world, and processes 3,000-4,000 outbound shipments per day. The facility has 28,000 pallet locations and more than 16,000 individual pick faces, including case pick and each pick locations across multiple zones with a variety of picking processes and technology.
The WMS provided RF-based work execution and integrated with conveyor and sortation systems, and a pick-to-light module for each picking. Despite using RF and pick-to-light, picking processes were complex and inefficient, causing frequent overtime.
Additionally, work release was highly manual. The WMS would print the labels for all orders for the day and a planner would sort the labels by carrier and shipment. The pickers would ultimately decide the sequence in which orders were picked, which sometimes caused items to ship late, among other issues. Errors and late shipments are especially costly when shipping to big box