Project Overview
KGP Co, a leading provider of supply chain solutions for the communications industry, partnered with Precision Warehouse Design (PWD) to launch a new warehouse operation in Fort Worth, Texas. The company needed a turnkey solution that would combine manual storage systems with automated sortation to streamline operations, increase throughput, and reduce labor dependency.
PWD delivered a comprehensive warehouse design and equipment installation package that enabled KGP Co to maximize space utilization, improve productivity, and enhance operational flexibility in their new facility.
The Challenge
As KGP Co expanded its distribution network, the company required a new warehouse in Fort Worth to support growing order volumes and regional service needs. Key requirements included:
- A fast-track warehouse launch with minimal disruption
- Integration of manual storage systems for diverse SKUs
- Deployment of automated sortation to support high-volume processing
- A cost-effective, labor-efficient solution that could scale with demand
The Solution
PWD provided a turnkey warehouse solution that seamlessly combined manual and automated systems to meet KGP Co’s operational goals. The scope of work included:
Custom Warehouse Design
- Developed an efficient warehouse layout that optimized flow, storage, and sortation areas
- Tailored the design to meet current operational needs while allowing for future scalability
Equipment Installation
- Industrial Pallet Racking: Implemented for high-density, organized manual storage
- Pushback Rack: Allowing for overstock storage while maximizing space.
- Pallet Flow Rack: Implemented for seamless product movement for high-volume picking.
- Carton Flow Rack: Implemented for product movement for medium-volume picking.
- Pick Module: Enabled fast picking and consolidation of orders across multiple levels through pushback racking for overstock, pallet flow lanes for high volume picking, and carton flow lanes for moderate moving items.
- Automated Conveyor Systems: Installed to move product efficiently between storage and sortation zones
- Automated Sortation Technology: Integrated to support high-speed order processing and reduce manual handling
All systems were installed and commissioned by PWD’s in-house engineering and project management teams, ensuring quality, safety, and on-time delivery.
Results & Impact
The new Fort Worth facility delivered measurable improvements for KGP Co:
- Increased storage capacity without expanding building footprint
- Reduced labor requirements through automation of repetitive tasks
- Boosted order fulfillment speed and overall building throughput
- Fully integrated systems designed for long-term scalability and ROI
With this hybrid approach—manual storage paired with automated sortation—KGP Co was able to launch a high-efficiency distribution center that supports current operational demands and future growth.
Conclusion
Precision Warehouse Design’s partnership with KGP Co showcases the power of integrated warehouse solutions that combine manual efficiency with automation. By delivering a turnkey system featuring racking, conveyor, pick modules, and smart sortation, PWD helped KGP Co reduce labor costs, accelerate order processing, and optimize facility performance.
Explore more about our Turnkey Warehouse Solutions or contact us to learn how we can support your next facility launch.
