Overview
Leading athletic footwear company receives inbound ocean containers from Port of Long Beach and struggles with cost per piece due to limitations in fulfillment capacity, inventory control, and storage capabilities. With a need to ship 80,000+ lines per day across retail store, wholesale, and direct to consumer, lines per order ranged from 100+ lines down to a single line order- all from the same DC.
Challenge
- 200 associates in 500,000 sqft
- 4 to 5 day order turnaround
- Inventory capacity limited to 2,000,000 units
- Heavily manual pick process with associates pushing carts
- Manually intensive cartonizing,labeling, and manifesting processes in different areas
- Highly dynamic and challenging SKU mix
- Higher cost per piece handled and processed
- 100 associates in 230,000 gift
Resolution
- Same day / next day shipping
- Inventory capacity expanded to 3,000,000 units
- Automated delivery process of orders to the pickers
- Automated carton sizing, labeling, weighing, and manifesting
- Automated sortation of parcels and LTL shipments
- Lower cost per piece handled, with capital investment ROI of 13 months
