The document discusses implementing a new distribution center for a wholesaler/retailer client to address challenges of an old facility being too small as sales expanded to four continents. It outlines the complexity of integrating new warehouse management systems, material handling automation, and compliance labeling requirements. The solution involved a waveless picking system using pick-to-light displays, automated conveyors, and an 11-lane sortation system to increase efficiency, reduce costs, and allow five-fold business growth while meeting all regulations. The results were a distribution center that was compliant, reduced processing costs and labor needs, and could be remotely supported.

1. By Bart Vanbelle

2. Table of content
• Who are we?
• The Case
• Challenges
• Solutions
• Results
• Summary

3. • Founded 2010
• Missing Link
• Consultants WMS
• WMS/WCM suppliers
• Passion for logistics
• Problem-solving attitude

4. The Case
New distribution center
• Why?
• Sales on four continents
• Market leader
• Innovative & creative
• Old distribution center to small
Stratham, New Hampshire

5. The Case
New distribution center
• Problems?
• Wholesaler/retailer
• Compliance labeling
• Governmental regulations
• Opportunities
• Cost reduction
• Automatization
• Efficiency
Stratham, New Hampshire

6. The Case
Complexity
• JD Edwards ERP.
• Missing link
• WMS
• WCS
• Warehouse automation
• Materiel handling
• Conveyor
• Sortation

7. The Case
Solution
• Waveless picking system
• Automated
• Movement of materials
• Flow of data
• Material handling systems
• Pick to light => quantity and lot
verification
• Sortation system => 11 sorting lanes
+1 exceptions + 1 recirculation lane
• Extensive network of conveyors
• 12 different types
• And much more

8. The Case
Solution
• Design capabilities
• Production lot control
• Identification, control and tracking
• Wholesaler/retailer compliance
labeling
• Real-time control of m.h.
Equipment
• System wide information flow
• High visibility of operations and
data

9. The Case
Inwards Flow
• Via a pallet conveyor
• Handled in FEFO
• Full traceability
Production
Warehouse
Extensive
storage and
retrieval area

10. The Case
Order fulfillment
ERP JD
Edwards
Fasttrak
•Waveless
picking
process
Pick-to-
light
displays
•Operators pick
cases from
pallet bays =>
conveyor
Route to
palletizing
Initiated the order fulfillment
Organizes orders & associated
replenishments

11. The Case
Order fulfillment
Print/appy
labeling system
Fasttrak ws uses
the barcode to
allocates the
inventory to orders
Outbound sliding
shoe sorter
Order/pallet
building proces

12. The Case
• Results
• Compliant
• Government regulations
• Client labeling demands
• Five-fold increase in business
• Processing cost reduced
• Labor requirements reduced
• Fully remotely supportable
• Software updates, analyze logs and trace files

13. • Innovation
• Challenges
• Automatization
• Implementation
• Follow-up
• Support