Warehouse Optimization & Mobile Picking
We re-slotted all 6 warehouses using ABC analysis, placing high-velocity items in golden zones closest to packing stations. The mobile picking app displayed optimized pick paths reducing travel by 42%. Batch picking allowed workers to pick multiple orders simultaneously, improving efficiency by 55%. Voice-directed picking for high-volume areas achieved 99.8% accuracy. Real-time dashboards showed picking productivity by worker, enabling performance coaching and incentive programs.
Perishable Goods & Expiration Management
The system tracked expiration dates for 35,000+ perishable SKUs, automatically enforcing FEFO (First Expired, First Out) picking rules. Mobile scanners flagged products within 7 days of expiration for immediate promotion or disposal. Automated alerts notified buyers when slow-moving items approached expiration, enabling proactive markdowns. Temperature monitoring integration sent real-time alerts for refrigeration failures, preventing $180K in spoilage during the first year alone.
Demand Forecasting & Automated Replenishment
Machine learning models analyzed historical sales data, incorporating factors like day of week, holidays, local events, and weather forecasts. The system achieved 87% forecast accuracy, automatically generating purchase orders when stock reached reorder points. Min/max levels were dynamically adjusted based on lead times and demand variability. Integration with supplier EDI systems enabled automated order transmission and receipt confirmation.
Implementation & Training
We executed a phased rollout, starting with a single warehouse pilot running parallel with the legacy system for 3 weeks. After validation, we rolled out to remaining warehouses over 12 weeks. We trained 280 warehouse staff through hands-on sessions using realistic scenarios. Super users received advanced training to become on-site champions. The comprehensive training program achieved 92% user adoption within 4 weeks of each warehouse going live.