CASE STUDIES

ASSESSMENT
Since the order profile for the additional demand that the warehouse was tasked to fulfill was primarily split case orders, it was determined that the capacity expansion was best accomplished by replacing the small put to light operation with a new, larger system located on top of the existing 35,000 square foot mezzanine that had been previously used for pallet storage.

SOLUTION
An inbound sortation line with scan tunnel, four put-to-light rows of shelf bays, an outbound full case take-away line, a trash conveyor system for empty corrugate boxes and an empty carton replenishment line were the key elements in the design. Outbound orders from the new system merged with the existing high speed conveyor and sortation system that provides for 200 sort locations that corresponds to pallet building stations for Home Depot store orders.

RESULT
The project was completed on budget and on schedule. Home Depot’s Carlisle facility now has the capacity to fill more orders and to better service its regional stores.