Project Overview
Precision Warehouse Design (PWD) partnered with Melissa & Doug, a leading specialty toy manufacturer, to upgrade their East and West Coast fulfillment centers. Facing rapid growth and increasing demand, Melissa & Doug required efficient, scalable solutions to enhance their distribution capabilities ahead of the busy holiday season. PWD successfully implemented advanced material handling systems within a tight four-month timeline, ensuring the facilities were prepared to meet seasonal demands.
Client Background
Melissa & Doug, founded in 1988 and headquartered in Connecticut, is renowned for its high-quality, open-ended toys that inspire imaginative play. The company has experienced double-digit growth in recent years, expanding its distribution channels both online and globally.
Project Goals
To support Melissa & Doug’s rapid expansion, PWD aimed to:
- Design and implement scalable warehouse systems to accommodate increased order volumes.
- Integrate advanced material handling technologies to streamline operations.
- Ensure timely project completion within a four-month window to prepare for peak season.
Solutions Implemented
PWD delivered comprehensive warehouse solutions, including:
- MHS Conveyor Systems: Installed sophisticated conveyor sortation systems on the loading docks, feeding 20 dock doors to facilitate efficient order processing.
- Datalogic 5-Sided Scan Tunnels: Integrated for accurate scanning and tracking of packages, enhancing inventory management and order accuracy.
- Interlake Mecalux Pallet Racking: Deployed to maximize storage capacity and improve organization within the 600,000+ square-foot facilities.
The new system enabled the scanning, analysis, weighing, and sorting of approximately 60 cartons per minute, significantly boosting operational efficiency.
Results and Impact
The collaboration between PWD and Melissa & Doug resulted in:
- Enhanced Operational Efficiency: Streamlined processes led to faster order fulfillment and reduced handling times.
- Scalable Infrastructure: The standardized design allowed for easy replication across multiple sites, supporting Melissa & Doug’s rapid expansion.
- Improved Customer Satisfaction: Efficient fulfillment centers contributed to timely deliveries, enhancing the customer experience.
Conclusion
Precision Warehouse Design’s partnership with Melissa & Doug exemplifies the successful implementation of scalable, efficient warehouse solutions tailored to the unique needs of a rapidly growing toy manufacturer. Through strategic design and integration of advanced systems, PWD enabled Melissa & Doug to meet growing customer demands and solidify its position in the global toy market.
For more information on our warehouse design services, visit our Warehouse Design Services page.
