Warehouse Workflow Automation (Transcarga Logistics)Intelligent Automation
The effort vastly improved the company’s picking and order-fulfillment functions; they knew that in order to succeed in this era of e-commerce logistics their warehouse operations needed to be much more automated than what they were. They turned to ALETERIS to automate their distribution center workflows.
challenge
The biggest challenge was that Transcarga Logistics was not utilizing automation properly inside its distribution centers. Too much of the picking, packing and order verification was still being done manually, which meant that orders took a long time to move through the warehouse and then to reach the dock. Live throughput visibility was also not available and staffing decisions could only be made after a shift had already fallen behind. This was holding Transcarga back; they knew they could handle more volume if they had the ability to automate the most repetitive parts of the workflow. The work addressed three critical issues for Transcarga Logistics:
Improve picking and order-verification throughput:
The teams focused their efforts on a few of the highest-value workflow levers in order to review the current warehouse process, identify gaps in the automation coverage and analytically understand order volume and complexity variability.
Determine the right automation & staffing model:
With order volumes fluctuating heavily across the week, Transcarga needed a proper method to decide which tasks to automate and how to staff the remaining manual work. Using a workflow-complexity analysis, the teams defined appropriate automation coverage for picking, packing and verification by mapping actual versus forecasted order volumes.
Optimize the layout for perfect fulfillment speed:
The diagnostic determined the stressors that affected fulfillment speed and error rates. The teams focused on resolving issues related to higher-than-normal manual handoffs and mis-picks, which stressed the entire distribution center and led to delays in orders reaching customers.
solution
The solution ALETERIS came up with combined cutting-edge workflow automation with real-world warehouse practicality. Everyone knew that the fulfillment process had to be automated, the real challenge was doing it without disrupting daily shipping volumes in a negative way. The solution was to introduce automated picking guidance and AI-driven order verification, while providing warehouse supervisors with live dashboards tracking throughput across every shift.
This allowed warehouse staff to be involved in exception handling instead of spending most of their time on repetitive manual checks.
results
Transcarga Logistics supervisors are now more empowered; Transcarga also has the benefit of tracking distribution center throughput instantaneously whenever needed. They can now make staffing and workflow decisions on the fly based on the latest real-time data.
The effort vastly improved the company’s picking and fulfillment functions, created and implemented a new automation coverage model that accounted for order complexity and peak-volume periods, streamlined the verification process and reduced fulfillment errors across the distribution center.
By the numbers, the effort:
Increased distribution center throughput by 35%
Decreased mis-pick rate by 50%
Lowered manual handoffs by 95%
Increased on-time shipment rate by 10%
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