Case Study: Staffing for Accelerated Distribution Center Launch

Situation:

• Urgent customer need to set up distribution center in 2 weeks
  
  
• Distribution center had specific requirements including:
  • 11 loading doors
  • 14 staging lanes
  • 8 unloading doors
    
    
• Initial request was for forklift drivers, but client realized complex task demanded experienced materials and warehousing experts 

Solution:

• Assigned two seasoned team leaders to the project
  • One expert held Lean Six Sigma Black Belt credentials and a track record of optimizing operational efficiency 
  • One expert proficient in operations and maintenance
    
    
• Warehouse Layout Optimization: Team leaders defined a dynamic inventory assignment layout
  
  
• Efficient Process Design: Designed an efficient put-away and pick process
  
  
• WMS Integration: Populated part location data into the Warehouse Management System (WMS) to manage thousands of SKUs 

Successes:

Exceeding Customer Targets: Successfully unloaded and put away over 100 trailers in the first week. Achieved 8,500 lines picked per day, compared to target of 7,000

Ahead of Schedule: Customer well-prepared to commence shipments ahead of the original schedule.

Management Focus: Customer's management team found itself freed up to focus on the second phase of the project earlier than anticipated.

Request for Additional Support: Customer requested additional team members from PSS to completely replace a competitor in the project.

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