Rotary Corporation

Transforming Fulfillment Operations To Meet Next-Day Delivery Demands While Reducing Labor Costs

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. 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. Part of the solution was the Lucas Work Execution system which provides optimized voice directed picking and replenishment alongside Rotary’s legacy LogPro warehouse management system (WMS).

Testimonial

“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

Voice-Directed Work Execution at Rotary

Lucas Engage work execution software integrates with the WMS and creates units of work to optimize pick density and throughput. It then orchestrates the picking across the reconfigured warehouse areas. Prior to the redesign, orders had to be segregated and picked by transport type (small parcel, LTL, etc.), using an RF process directed by the WMS. Engage also 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.

In the new system, workers in the DC use Lucas Move mobile applications, featuring Jennifer voice, for picking and replenishment. The voice directed picking application provides a hands and eyes-free process while enabling the creation of new workflows like bucket brigade and pick-to-tote styles for fast moving piece pick items.

Results

  1. 1) 99.9% same-day shipping
    2) Reduced picking hours 25% while increasing volume
    3) New records for daily and monthly shipping volumes
    4) Replenishment productivity increased 10%
    5) Increased picking accuracy
    6) Reduced training and eliminated seasonal temps
    7) Increased wages and reduced total labor costs

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