Case Studies
Warehouse Software Case Studies
| Company | Industry | Download |
| Fidelity Investments | Book & Publication Distribution |  |
Warehouse Rx - WMS |
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| Distributing more than 120 million pieces of mail to individual clients worldwide each year would be a tough assignment for any company. But for Fidelity Investments, one of the world's largest managers of mutual funds, handling the distribution of financial product literature from two centers across the country made the assignment even trickier. Adding to the challenge, both centers were running out of capacity due to Fidelity's rapid growth. The company solved the problem by consolidating its two printing and distribution centers into one facility, located near Cincinnati. Daifuku America's fully integrated system gives Fidelity unprecedented speed in order picking, continuous inventory tracking, significantly more throughput in less space, near perfect order fulfillment, and the virtual elimination of inventory-related paperwork. And the system does it all in far less space. |
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| Company | Industry | Download |
| Hargrove | Manufacturing | |
Warehouse Rx - WMS |
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| Hargrove Manufacturing Corp. manufactures gas fire cement logs for fireplace specialty dealers and distributors in the United States and Canada. To reduce production time, make more efficient use of available floor space, and reduce workers' compensation claims, the company decided to make the leap from a manual, labor-intensive production process to an automated material handling system. A relatively small company with $5 million in annual sales, Hargrove purchased a unit load Automated Storage and Retrieval System (AS/RS). The AS/RS frees up 80% of the floor space used in the company's old process and keeps the production pipeline flowing smoothly, with virtually no downtime. Since the AS/RS system was installed, log production at the Sand Springs, OK plant has increased by 100% with no increase in manpower. Product quality has significantly improved, and the company has achieved a 40% reduction in order-filling cycle time. Hargrove also expects a dramatic decrease in workers' compensation claims, due to reduced lifting and manual handling. |
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| Company | Industry | Download |
| Kasai Works | Manufacturing | |
Warehouse Rx - WMS |
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| Kasai Works, a manufacturer of car parts, knew that its system for storing its 400 molds on sliding shelves took up a lot of space, and manually removing a mold each time it was needed was a slow process. Kasai found that its inventory count was very inaccurate. Daifuku was able to free up a significant amount of space in Kansai’s facility, which allowed the company to install additional pressing machines. Daifuku also introduced inventory control software, which greatly enhanced location management at the plant. By installing the AS/RS system, Kasai saw the time required to locate and transport a mold to the pressing machine reduces to one-tenth the amount of time required with the old system. | ||
| Company | Industry | Download |
| Netto | Food & Beverage | |
Warehouse Rx - WMS |
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| In August 2000, eleven major material handling companies in Europe bid on the automation work for Netto’s new distribution center in Koge, near Copenhagen, Denmark. Daifuku was selected, and formed a close alliance with ABB, an affiliate, and other dominate material handling makers in Denmark to successfully complete the largest project for the European market on time. The Koge distribution center utilizes Daifuku’s Unit Load Automated Storage/Retrieval System (AS/RS), 40 high speed Storage Transfer Vehicles (STVs), and Warehouse Management System (WMS by ABB). Netto regards its new distribution center as the first step toward modernizing supply chains across the company. Netto won the 2004 Denmark Logistics award as a result of its consistent efforts in logistics activities and achieving cost reduction and increased work efficiency at its new distribution center. |
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| Company | Industry | Download |
| Northwest Airlines | Manufacturing | |
Warehouse Rx - WMS |
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| Airlines know that Airplane on Ground (AOG) situations can be costly, both in lost productivity and unhappy customers. Northwest Airlines found the best way to minimize AOGs is to get the necessary parts to its mechanics as quickly as possible. A new automated parts warehouse was built to provide parts for line and heavy maintenance mechanics in Minneapolis, as well as for Northwest's two other major maintenance facilities and 51 line maintenance stations worldwide. In all, the warehouse averages 32,000 parts orders per month. Northwest has reduced cycle time for picking parts orders by 60%, cutting delivery time to mechanics by 21%. Although faster order picking -- especially for AOG orders -- was Northwest's first priority, the Daifuku America system has provided several other benefits. Productivity has nearly doubled, and stock clerks no longer have to stoop or stretch to reach parts since the mini load delivers them to the workstation at an ergonomic level. The end result of Northwest's investment is faster parts deliveries to the mechanics that maintain the airline's fleet of more than 400 aircraft. |
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| Company | Industry | Download |
| O.C. Tanner | Manufacturing | |
Warehouse Rx - WMS |
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| In the early 1990s the trend line for merchandise awards continued up for O.C. Tanner - but so did the requirement for storage space, requiring the leasing of off-site warehouses. Eventually, O.C. Tanner built a new, automated Award Distribution Center in Salt Lake City. The craftsmanship content of the merchandise awards process was not changed, but the manual material handling and the chasing back and forth to complete orders was automated. Previously, a worker walked as much as 5,100 feet to take an order through the manufacturing and shipping processes. With the new system, merchandise is conveyed to and from the workstations to minimize walking. Output increased dramatically from 1,800 awards per day to 3,000. Worker efficiency went from 3.5 awards per worker hour to 5.5 awards per hour with 45% fewer people. Cycle time from order entry to shipment was reduced by half to three to four weeks. |
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| Company | Industry | Download |
| Winzer | Manufacturing | |
Warehouse Rx - WMS |
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| The consistent double-digit growth year in and year out at Winzer Corporation is attributed to its unique franchising system. Winzer Corporation is a distributor of fasteners and repair and maintenance supplies for the industrial and automotive markets. In response to the rapid growth and success it was experiencing, Winzer looked to Daifuku for help. Daifuku helped implement a hybrid semi-automated system for Winzer’s “pick, bag, and tag” operations. Winzer found that by automating a few key areas, it could provide more assistance to its franchises. Daifuku installed 60 Put-to-Light consolidation locations to ensure that picked products fill the appropriate orders, among other products and automation tools. The entire system is controlled by Daifuku America’s Warehouse Management Software (WMS), Warehouse Rx®. With the new equipment and control software, the company is able to keep its growth rate in the double digits while fulfilling its promises to franchises nationwide. |
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| Company | Industry | Download |
| Utah ABC | Food & Beverage | |
Warehouse RX - WCS |
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| Utah is one of 18 states that controls alcoholic beverages sales at either the wholesale or retail level. The Department of Alcoholic Beverage Control (DABC) has been charged with meeting growing consumer demand for alcoholic beverages while protecting the public interest. This translates into keeping the individual customer happy by making sure the retail outlets are well stocked with lots of variety in an efficient and cost-effective manner. An increasing population and growing tourism following the 2002 Winter Olympics in Salt Lake City placed a burden on existing inventory. Utah DABC was quick to respond by expanding their facility to handle the overstock needed to fulfill orders during seasonal peaks. The new expansion increased capacity while virtually eliminating conditions such as overcrowding, product damage, lost inventory and aisle congestion. At the same time, it increased the quality of employee work life with a more ergonomic system. That's a pretty tall order by anyone's standards, but Utah DABC was up to the challenge. Unit Load AS/RS5 aisle of Unit Load AS/RS has 6160 pallet locations pallet storage and order picking area are connected by conveyors |
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| Company | Industry | Download |
| Utah State University | Libraries | |
Warehouse RX - WCS |
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| Utah State University (USU), located in Logan, Utah, brought Daifuku America Corporation on board to help it with some issues the university library was facing as it moved to a new facility. The university needed an innovative solution to accommodate growth through the year 2027. To meet USU’s needs, Daifuku provided the expertise and equipment to get the new facility up and running. USU implemented a Mini Load Automated Storage/Retrieval System (AS/RS). USU’s Merrill-Cazier Library system is the only library in the world to use an automated retrieval system with materials in call number order. The system allows patrons the opportunity to pull up a chair and browse approximately 200 to 250 volumes at a time once the shelf they need is automatically brought to them. |
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| Company | Industry | Download |
| Winzer | Manufacturing | |
Warehouse RX - WCS |
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| The consistent double-digit growth year in and year out at Winzer Corporation is attributed to its unique franchising system. Winzer Corporation is a distributor of fasteners and repair and maintenance supplies for the industrial and automotive markets. In response to the rapid growth and success it was experiencing, Winzer looked to Daifuku for help. Daifuku helped implement a hybrid semi-automated system for Winzer’s “pick, bag, and tag” operations. Winzer found that by automating a few key areas, it could provide more assistance to its franchises. Daifuku installed 60 Put-to-Light consolidation locations to ensure that picked products fill the appropriate orders, among other products and automation tools. The entire system is controlled by Daifuku America’s Warehouse Management Software (WMS), Warehouse Rx®. With the new equipment and control software, the company is able to keep its growth rate in the double digits while fulfilling its promises to franchises nationwide. |
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