Project Overview
A leading provider of industrial and construction machinery for a specific US Based manufacturer had a growing distribution operation that was experiencing operational strain due to heavy reliance on manual picking, packing, and sortation. These labor-intensive processes made it difficult to scale, increased fulfillment times, and limited order accuracy.
To address these challenges, PWD delivered a comprehensive automation solution featuring an OPEX Perfect Pick automated picking system, a three-level pick module, conveyor sortation system, and an advanced OPEX interface system that integrates seamlessly with the company’s WMS. The result was a dramatically streamlined operation with increased throughput and reduced labor dependency.
The Challenge
With increasing order volume and pressure to ship faster, the company recognized that its manual fulfillment process was no longer sustainable.
Primary challenges included:
- Excessive manual labor required for picking, sorting, and packing
- Lack of available manpower in the market
- Limited scalability of existing workflows
- A need for reliable automation to reduce errors and meet customer expectations
- Inadequate system integration between existing hardware and warehouse software
The Solution
PWD delivered a high-efficiency, scalable warehouse automation system designed to improve performance from picking to shipping:
OPEX Perfect Pick Automated Picking System
- Installed an OPEX Perfect Pick automated storage and retrieval system (AS/RS) that uses robots to deliver inventory directly to operators.
- This dense storage solution allowed them to maximize their building’s cubic space and simplify their order fulfillment process.
Multi-Level Pick Module
- A three-level pick module was installed to maximize vertical space utilization and improve pick efficiency with zone routing capability.
- Enabled order consolidation from multiple zones, reducing travel time and labor requirements.
Automated Sortation System
- Installed two high-performance sortation conveyor systems to handle parcel distribution and routing with speed and precision.
- Enabled real-time carrier-specific sorting, improving downstream shipping efficiency for LTL shipments.
OPEX Interface System
- Integrated an interface between the pick module and the company’s WMS.
- Implemented queuing logic to efficiently manage tote flow between the pick line and OPEX sortation points.
- Ensured seamless data exchange between automation equipment and software, improving operational visibility and control.
Results & Impact
The integrated automation solution delivered significant operational improvements for the company:
- Streamlined picking, packing, and shipping workflows
- Increased throughput, allowing the facility to process more orders with fewer human resources
- Improved order accuracy and consistency
- Reduced labor dependency, lowering overhead and improving scalability
By transforming its fulfillment infrastructure, the company is now positioned for sustainable growth and improved customer satisfaction.
Conclusion
This case study exemplifies PWD’s ability to deliver smart, tailored automation solutions that bridge the gap between labor-heavy workflows and high-efficiency distribution operations. With a powerful combination of structural design, automation hardware, and intelligent integration, PWD helped this company future-proof its operations and unlock scalable throughput.
