Project Overview
An electronics repair and logistics services provider based in Houston, Texas, invested in a cubic Automated Storage and Retrieval System (AS/RS) to increase efficiency and reduce labor dependency. However, the company struggled to realize the expected ROI due to manual transportation and sortation processes both upstream and downstream of the AS/RS system.
Precision Warehouse Design (PWD) stepped in to deliver a fully integrated automated conveyance and sortation system that enhanced the flow of goods, reduced errors, and unlocked the full value of company’s AS/RS investment.
The Challenge
Despite the advanced capabilities of their AS/RS, company’s upstream and downstream operations remained manual and labor-intensive, limiting the overall impact of automation on the fulfillment process.
Key operational pain points included:
- Manual sortation of outbound parcels, leading to slower shipping speeds
- Bottlenecks caused by inefficient movement of goods between AS/RS and shipping zones
- Underutilized AS/RS system, preventing realization of expected return on investment
- Limited data visibility for package volume tracking and staffing optimization
To capitalize on their automation investment, the company needed an integrated solution to bridge the gap between high-speed storage and shipping operations.
The Solution
PWD designed and implemented a custom conveyance and automated sortation solution specifically engineered to support the AS/RS workflows.
Automated Conveyance System
- Installed conveyor lines that seamlessly connected inbound and outbound material flow to and from the AS/RS
- Ensured smooth, high-speed movement of parcels, eliminating delays caused by manual handling
Automated Sortation Technology
- Integrated automated carrier-specific parcel sortation to improve shipping efficiency and reduce errors
- Increased daily throughput while ensuring accurate sorting by UPS, FedEx, USPS, and other carriers
Real-Time Tracking & Reporting with Ignition Software
- Implemented Ignition SCADA Software to provide real-time visibility into:
- Package volume by carrier
- Sortation performance
- Labor allocation by area
This software allowed the company to better allocate staffing, monitor key performance indicators, and continually optimize their parcel fulfillment operations.
Results & Impact
The company’s investment in integrated automation delivered significant operational gains:
- Substantial increase in shipping throughput
- Improved accuracy in outbound parcel sorting, reducing error rates
- Eliminated manual bottlenecks, enabling the AS/RS system to reach its full potential
- Achieved ROI on their AS/RS investment through direct integration with shipping operations
- Gained data-driven control over operations via Ignition Software
This transformation allowed the company to better meet customer demand, increase fulfillment speed, and reduce operational costs.
Conclusion
This project highlights Precision Warehouse Design’s ability to design and implement end-to-end warehouse automation solutions that enhance the performance of existing technologies. By integrating automated conveyance and sortation with the company’s AS/RS, PWD helped turn an underperforming investment into a high-throughput, data-driven fulfillment engine.
👉 Explore our Automated Sortation Solutions or contact us to optimize your warehouse automation strategy.
