Rotary Transforms Fulfillment Operations To Meet Next-Day Delivery Demands

In the face of rising demand and shipping volumes, the management team at Rotary Corp. recognized that their current fulfillment systems and processes would not be able to meet their customers’ next-day delivery demands. Rather than building from scratch, the company embarked on a seven-month project to reconfigure it’s 250,000 square foot central DC and reengineer it’s fulfillment processes with Lucas.

Rotary Case Study: Increasing Throughput with Less Labor

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With the help of Lucas, Rotary Corporation has seen a 40% increase in throughput while reducing labor by 20%. See how the Lucas Optimization Suite has empowered Rotary to cross-train employees and better utilize their warehouse workers.

“We began the journey with a detailed assessment and financial analysis of multiple alternatives. This ultimately resulted in a new and enhanced process flow for our shipping operations including warehouse inventory management, automated voice selection, advanced handling equipment and a redesigned conveyor system.”

Ed Nelson, President and CEO

The Lucas Solution

The Lucas solution includes unique AI-based optimization that is embodied in Jennifer™, the brains, voice and orchestration engine of the solution.
Lucas uses order, inventory and task information from Rotary’s legacy LogPro WMS, and Jennifer™ creates units of work to optimize pick density and throughput. Jennifer™ orchestrates the picking across the reconfigured warehouse areas.
The Lucas management console provides dashboards that give managers and supervisors real-time visibility into work in process, associate productivity, and exceptions, helping them to efficiently allocate staff and manage work.
Optimized voice directed picking and replenishment.
Optimized workflows like bucket brigade and pick-to-tote styles for fast moving piece pick items.

The Results

99.9% same-day shipping
Reduced picking hours 25% while increasing volume
New records for daily and monthly shipping volumes
Replenishment productivity increased 10%
Increased picking accuracy
Increased wages and reduced total labor costs

About Rotary Corp

Rotary, based in Glennville, GA is the world’s largest supplier of outdoor power equipment parts, tools and accessories, serving mass merchants, OEMs, repair shops and domestic and international distributors.