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Third Party Logistics

Spartan Graphics

Overview
Results

Business Issues:

Aggressive implementation schedule of 9 weeks
High order throughput of 4,000+ orders per four day fulfillment cycle
Order visibility among Spartan, client management, and field sales
On-line order entry capabilities
Ease of use/low training requirements for temp workforce

Technical Issues:

When Spartan management visited the incumbent's distribution center, they observed a manual fulfillment process that required a staff of approximately 100 workers to complete the orders. The fulfillment process runs on a monthly cycle. The process begins when materials are printed by Spartan and placed on pallets within the distribution facility for storage. A typical print cycle includes approximately 30 to 80 items including floor decals, cart ads and coupons. During the last three to four days of the monthly cycle, the decals are packaged and shipped to field sales representatives who distribute among the retail stores. Approximately 2,000 orders consisting of 20 to 80 individual items are picked within the three to four day period. Spartan decided to utilize temporary workers due to the cyclical nature of the operation.

Spartan Graphics needed a Warehouse Management System that would provide accuracy, efficiency and visibility of the inventory. FLOORgraphics also desired additional services including management reporting, browser based order visibility, and on-line order entry. Spartan needed to deploy this solution within a nine week period.

Solutions:

To meet these requirements, Spartan Graphics, deployed ASAP Automation's ExactaÂ® WMS , Light Directed Picking, and Exacta® Order Management Software. ASAP Automation provided a turn-key solution including engineering and facility design, material handling equipment and technologies, implementation, and support.

ASAP Automation designed a system utilizing Exacta Light Directed Picking technology to provide high volume picking efficiency and accuracy. Spartan is able to pick 10,000 line items per day with six operators.Exacta LDP offers a paperless pick method which dramatically increases pick rates over RF or paper processes. It also offers an easy to use solution which reduces the training time and potential pick errors associated with the temporary workforce.

Exacta WMS was implemented to provide accurate inventory control and efficient order processing. The Warehouse Management Software included order import, order assignment, order association with carton size selection, full tote capability, cycle counting, weight verification, and pack with integration to FedExâ„¢ Powership MC manifest software.

Spartan also utilized the Exacta Order Management System in order to enhance the user experience and order visibility among the FLOORgraphics's management and field sales staff. The OMS provides visibility into inventory and order data through an easy to use browser application. The field sales rep can also place an order on-line using a shopping cart and track the progress of the order through delivery with a real time link to FedEx. Management reporting is also deployed through the Order Management Software application to enable FLOORgraphics executives to view customized order and warehouse performance reports.

Key Technology:

Results

Reduced labor requirements from 100 to 12, while increasing order throughput.
Consolidation of two distribution facilities.
High order accuracy.
Order status visibility through the World Wide Web.
Browser based order entry eliminating the need for call center staff.
Deployment of performance reports through browser based application.

Solutions Simplified.