Project Overview
Waco Shoe Company, based in Waco, Texas, partnered with Precision Warehouse Design (PWD) to dramatically reduce fulfillment time for seasonal spikes driven by QVC airings. Each year, QVC broadcasts four major campaigns featuring Waco Shoe Company’s products, triggering 15,000+ orders per event. Previously, it took up to two weeks to fulfill these orders using a manual process — causing delivery delays and customer dissatisfaction.
PWD engineered a custom three-level automated pack line, enabling the company to meet QVC’s demand and ship all 15,000 orders in just three days, a 5x improvement in fulfillment speed.
The Challenge
Waco Shoe Company faced a unique high-volume, high-speed challenge:
- 15,000 shoes needed to ship out immediately after each of four QVC broadcast events annually
- Legacy manual packing systems required up to two weeks to fulfill orders, delaying customer deliveries
- QVC shoppers expected delivery within 5–7 days, placing immense pressure on warehouse operations
To stay competitive and satisfy customer expectations, Waco Shoe Company needed a streamlined, automated solution that could handle peak demand with speed and accuracy.
The Solution
PWD designed and installed a cost-effective, high-speed automated fulfillment system centered around a three-level pack line:
Three-Level Pack Line Design
- Level 1: Shipping Conveyor
- High-speed MHS takeaway conveyor leading to dock doors
- Level 2: Bag Conveyor Line
- Products bagged and routed to gaylords via b conveyor system
- Level 3: Trash Conveyor
- Waste materials funneled away using a separate belt conveyor system
High-Speed Sorting by Carrier
- Cognex top-side camera scanners read each shipping barcode
- Orders automatically sorted by carrier: UPS, FedEx, USPS
- 30° all-electric 24V diverts ensure accurate and efficient sortation
Equipment & Technologies Implemented
- MHS Conveyor with 24V ITR for energy-efficient performance
- FMH PowerFlex flexible conveyors for dynamic loading flexibility
- Allen-Bradley PLC controls for reliable automation
- PrecisionWare 360 by Ignition SCADA software to manage and visualize system performance
Results & Impact
The solution delivered transformational improvements for Waco Shoe Company:
- 15,000 orders shipped in 3 days (down from 14 days)
- 30 packages per minute throughput to dock doors
- ROI in less than 6 months on a $375,000 investment
- Dramatic boost in revenue velocity and customer satisfaction
With this automated solution in place, Waco Shoe Company can now confidently meet QVC’s high-volume demand, align with customer delivery expectations, and generate revenue faster.
Conclusion
This project highlights Precision Warehouse Design’s expertise in designing fast, scalable, and cost-efficient fulfillment systems for high-pressure, seasonal operations. By integrating smart conveyor technology, advanced barcode scanning, and automated sortation, PWD delivered a high-performance pack line that dramatically reduced fulfillment time and provided a rapid return on investment.
Learn more about our Pack Line & Sortation Solutions or Request a Consultation to optimize your own fulfillment operations.