Project Overview
Precision Warehouse Design (PWD) partnered with this national apparel wholesaler to create a cutting-edge conveyor and software integration solution. The objective was to automate the induction of SKUs from inbound cartons into an existing Pop Pick system, significantly increasing throughput and operational efficiency.
Client Background
This leading national wholesaler of premium imprintable apparel and accessories had a vast SKU count and high daily order volumes requiring them to streamline inbound handling and optimize robotic picking for greater accuracy and efficiency.
The Challenge
This national apparel wholesaler required a conveyor system that could seamlessly integrate with their inbound processes. The primary goal was to enable operators to decant SKUs from inbound cartons into totes, which would then be automatically inducted into the Pop Pick robotic system.
Key challenges included:
- Enabling precise weight validation of totes before induction
- Maintaining real-time communication between systems (WMS, conveyor, and Pop Pick)
- Designing ergonomic and safe operator workspaces
- Ensuring high-volume throughput for peak daily operations
The Solution
PWD engineered a comprehensive conveyor and software solution, combining advanced hardware design with intelligent warehouse software integration:
Automated Conveyor System
- Totes are scanned, weighed, and sorted before being inducted into the Pop Pick system.
- Integration with this national apparel wholesaler’s WMS checks the actual vs. expected weight of inbound totes, validating SKU quantity accuracy in real time.
PrecisionWare360 Software – powered by Ignition
- An open architecture SCADA software developed on Ignition platform
- Acts as the middleware between the WMS and the robotic picking system.
- Communicates full line status of empty totes directly to the Pop Pick system, allowing for dynamic and efficient assignment of mobile robot tasks.
Integrated Facility Enhancements
- Floor preparation for the mobile robot environment
- Installation of ergonomic operator platforms to streamline tote handling
- Deployment of carton flow racking for shipping carton replenishment
- Installation of safety fencing and highway guardrails to secure the Pop Pick environment
Results & Impact
This auto-induction conveyor system enabled:
- 80,000 lines picked per day
- 15,000–16,000 orders fulfilled daily
- Over 60,000 SKUs stored and inducted via PWD’s conveyor system
By leveraging automation and seamless software integration, this wholesaler dramatically improved operational velocity, order accuracy, and labor productivity—setting a new standard for warehouse innovation in the apparel distribution sector.
Conclusion
This pioneering project underscores Precision Warehouse Design’s ability to deliver tailored, high-efficiency warehouse automation solutions that integrate seamlessly with robotics and warehouse management systems. From conveyor design and floor readiness to software integration and ergonomic operator environments, PWD empowers businesses like this national apparel wholesaler to scale fulfillment operations with confidence.
Learn more about our custom Automated Conveyor Solutions and Warehouse Software Integration for e-commerce and distribution operations.
