CASE STUDIES

ASSESSMENT
During the Needs Analysis process, an area was identified within their warehouse that was not being used efficiently and could be relocated and combined with other areas within the building.

SOLUTION
A storage operation solution was installed, incorporating over 3,100 bays of closed style clip-type shelving with each bay containing five shelf levels. This shelving was the ideal storage medium for the e-commerce operations based on the typical order profile that Bealls was experiencing. The shelving was broken down into 8 areas on the mezzanine and included a 418-ft long zero pressure, photo eye accumulation conveyor leading to a declining spiral conveyor that brings totes to the ground floor operation. At the ground floor, associates pull totes off of the conveyor at the packstation area where they prepare orders for parcel shipment. Once packed and labeled, cartons are placed on an outbound conveyor and conveyed to the shipping dock where they are loaded onto a truck using powered flexible conveyors.

RESULT
By consolidating the e-commerce operation away from the retail and outlet operations, Bealls saw an increase in picking speed by upwards of 20-25% and a significant decrease in the amount of labor and transportation costs needed to fill orders for this growing sales channel.

ROI
18 to 24 months