U.S. Bakery Distributor Significantly Increases Productivity and Capacity of Existing Operation

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Client / Industry

A large bakery products distributor located in the U.S. Midwest, servicing in-store and independent bakeries.

Scope of KOM International's Mandate

The client required increased throughput capacity. KOM International redesigned the existing facility's storage methods and picking systems resulting in increased storage capacity and overall labor productivity improvements.

Critical Issues

• Shortage of storage capacity
  
  
• Distribution efficiency

Objectives

• Improve operational layout and procedural flows
  

KOM International's Recommendations

• Elimination of outside storage
  
  
• Introduced double-deep racks for bulk storage and order selection
  
  
• Introduced case flow racks and shelving units for slow moving items
  
  
• Introduced batch picking of multiple orders in one trip through the aisles to reduce operator travel time
  
  
• Optimized the picking sequence to improve pallet stability during transit
  
  
• Renumbering of aisles to force Z-pick travel thereby eliminating two-way travel in pick aisles
  
  
• Increased dock areas to improve staging and loading operations
  
  
• Immediate dock loading of picked orders

Benefits

• Increased storage capacity of existing building by 38% without any construction
  
  
• Doubled the number of operating aisles creating more pick faces and reducing aisle congestion
  
  
• Labor productivity improved by 48%