Case Study: Retail Mass Merchandiser

KLG worked with this mass merchandiser to build a 655,000 square foot distribution center in Lancaster, TX. The new system gives them increased efficiency and capacity in material handling to assist in delivering products to current stores and expanding further into the western US.

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LOCATION:
Lancaster, TX

SQUARE FOOTAGE:
655,000 square feet

PROJECT VALUE:
$13.48 M

PRODUCTS HANDLED:
Full cases – Mass merchandise

THROUGHPUT/CAPACITY:

  • We are looking to achieve 180CPM with the opportunity to achieve a max of 200 CPM
  • 32,000 pallet positions of selective

SKUs:
20,000 – 25,000 depending on season

PEOPLE/SHIFTS:

  • 5 days a week, 1 shift per day, 6:00 am – 3:00 pm
  • Future 2nd shift

SYSTEM HARDWARE/SOFTWARE:
WCS software control system

SYSTEM HARDWARE/SOFTWARE:

  • Intelligrated and Automotion conveyor in Unarco Pick Modules.
  • Camera scanner top read
  • Put-to-light system
  • Voice pick system
  • 2 – 3 deep full case pick modules
  • 1 – 2 deep full case pick modules
  • 1 – Slapper Line Induct area
  • Conveyor system 180 CPM
  • 8 to 1 merge
  • High-Speed Singulator
  • 29 Lane high-speed shoe sorter
  • 28 fluid load truck loaders