Cross-traffic, worker safety, equipment preservation, and better management of order packing were concerns expressed before the re-design of this large, regional distribution center. The new design had to incorporate radio frequency technology already in use.
Changes to every area of the facility needed to be incorporated and all changes would have to be made during normal production hours, without affecting service. Storage and picking of non-conveyable products were to be accommodated in the final design.
Because of intense sales growth, a national internet provider of sporting goods was rapidly running out of space. The resulting congestion was leading to order fill-rate, productivity, and accuracy problems.
Existing storage media, which was completely full, consisted mostly of wire shelving. Batch-order picking was carried out in a serpentine fashion—using carts.
Sales increases were expected to continue – causing more congestion, and leading to greater productivity, throughput, and accuracy problems.
Billy Goat Industries is a US manufacturer of premium grade power equipment for residential, commercial and institutional markets. They have developed innovative designs for aerators, dethatchers, over seeders, high grass mowers, composite leaf blowers, lawn vacuums and related equipment. They are a large exporter that has stocking dealers and service centers throughout the world. They have a strong presence in the rental markets.
As with most growing companies, Billy Goat needed more room in their existing facility. Therefore, they wanted to streamline their material flow through their plant to reduce congestion and waste.
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