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Success Story – 200% Productivity Boost

A Systems Integration Project

Numina’s warehouse automation solution helped Merit Medical increase  throughput, reduce  labor, and meet critical same-day priority shipments.

Background

Merit Medical, a major medical and surgical supply manufacturer headquartered near Salt Lake City, Utah moved into a new distribution center in Virginia, doubling the size of their previous East Coast location.

Challenge

Continuous growth was limiting Merit’s ability to get orders out on time. They were forced to add overtime hours and temporary employees but still could not meet demand.

Solution

The Numina Group helped Merit Medical replace its single-order pick-to-paper process with an advanced, automated order fulfillment solution.

The solution included integrating Numina Group’s RDS™ Warehouse Execution and Control System to manage and enforce better pick, pack, and ship processes. The new solution was implemented with minimal downtime or interference to Merit’s normal operations.

Results

The results were better processes and technologies that optimized the entire order fulfillment operation by reducing labor, increasing throughput, and successfully managing the critical same day priority shipments.

Watch the video below to see how Merit Medical has transformed its pick, pack and ship operations: 

Warehouse Automation Design Plan

After reviewing Merit Medical’s operational requirements, the Numina Group worked with the client to devise a warehouse automation design plan to meet order fulfillment productivity requirements. The new plan included:

Fast, High-Efficiency Picking Strategies

The new plan replaced single-order picking with batch picking in multiple processes, optimized by Numina’s RDS Warehouse Execution and Control System:

  • Single order picking was replaced with batch picking based on priority and work demand.
  • Orders would be picked simultaneously across the entire warehouse in a combination of fork truck cart picking, case pick-to-conveyor, pick-to tote, pick-to-pallet, full-pallet picking, and VNA vehicle picking.
  • Simultaneous batch picking of different order types would take place, enabling pickers to visit locations fewer times per shift. 
  • Voice picking technology would be added to guide pickers’ tasks, remove touches, and improve accuracy to 99.9% 
  • Unique order-specific barcode labels with lot serial number were added for tracking and
    conveyor routing.

RDS Pack and Ship Automation to Reduce Labor Costs

Numina’s RDS WES-WCS platform also included pack-and-ship automation modules to reduce manual tasks and streamline labor. The RDS odules include:

  • Put-to-light order consolidation for repacking to save time in the picking process and lower shipping costs.
  • Automated touchless in-line scan-weigh-dimension and auto-capture of carton contents.
  • Print-and-apply labeling system to automate the shipping manifesting, labeling, and application of the packing sheet.
  • LTL order fulfillment pallet build
  • Auto-sortation of cartons to the carrier trailer loading lanes.

RDS WES-WCS Benefits

Optimizing and automated Merit Medical’s  pick, pack, and ship processes has yielded substantial savings and quickly justified the investment, resulting in a rapid ROI.

Numina Group’s warehouse automation design recommendations and RDS WES-WCS platform have delivered the following improvements for Merit Medical:

To learn how we can help you achieve better processes and a rapid ROI, fill out a contact us form.

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