Ice Cream Manufacturer Resets Distribution Facility

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Client / Industry

A manufacturer/distributor of frozen products servicing retail outlets across the U.S. Midwest with ice cream and sundries product lines.

Scope of KOM International's Mandate

The client's freezer distribution facilities required expansion and a reset to increase flexibility, productivity and loading times. KOM International was commissioned to evaluate alternative materials handling systems, and to design and implement a new facility expansion.

Critical Issues

• Shortage of storage capacity
  
  
• Labor productivity
  
  
• Long dock loading times

Objectives

• Expand frozen food facility
  
  
• Select and implement a WMS with RF / bar coding technology
  

KOM International's Recommendations

• A new 40-foot clear stacking height freezer expansion was designed and implemented.
  
  
• A mechanized pick-to-belt system was replaced with a conventional pick-to-pallet system to increase flexibility
  
  
• Mix of single and double deep racks
  
  
• Designed a custom plastic pallet to fit in the Frozen trailers
  
  
• Reorganized product sequencing to build better quality pallet loads
  
  
• Changed pallet heights to increase storage capacity
  
  
• Introduced double pallet jacks to pick two orders in one trip

Benefits

• Facility expansion increased storage capacity by over 2,000 pallets
  
  
• Maximized storage capacity utilization of existing site
  
  
• 15% increase in warehouse labor productivity
  
  
• With the addition of three new truck doors, the overall shipping and receiving capacity increased by 50%
  
  
• Loading speeds increased by enabling the concurrent loading of multiple trucks