Specific SCM Solutions

Flexibility, which had to consider the need to handle seasonal peak levels of flow, was important in the facility design. It also had to handle expected changes in the mix of product that would occur over time. Flexibility was also required in terms of staff utilization. Quick turnaround and labor efficiency were more important than utilizing space. 

To address the peak inbound flow and inventory build-up, which occurs about a month prior to peak shipping activity, sufficient dock doors and dock operations area were provided. Secured trailer and ocean-container parking spots were designed into the site plan to add flexibility to inbound operations. 

Storage modules were planned to accommodate the present inventory mix. That mix ranges from small lots of cartons to multiple pallet quantities of tall pallets. A combination of decked shelf-rack modules and two opening sizes in pallet racks were designed. The start-up design allowed for open space between the two sets of modules for future rack expansion that would accommodate changes in the inventory mix. 

The tailored value-added processing requirements of the various customers were considered in the material flow and workstation designs for the processing stations. The flexible use of workstations was a primary consideration. The philosophy of the process design was to have more workstations than staff to allow dedicated workstations to be set up in advance with all the materials needed for a particular order. When a processing crew finishes one job, they leave the finished work for a material-handling crew to remove and they move to another set of workstations that has been set up for the next production order. 

The mechanized workstations for the dunnage fill and carton sealing workstations were designed around the supply chain requirements for surge and seasonal volumes, protective packaging of fragile products, and variable shipping carton dimensions. 

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