Melaleuca Material Handling Case Study

Key Technology

ASAP PictureView Pick To Display (PTD) Order Picking
One 2-level pick module
Tri-lane pick module conveyors utilizing high speed Bi-directional diverts (22 cases per minute)
Ermanco narrow belt sorter for pack
Mettler-Toledo in motion check weighing systems
Hytrol pre-sort Shoe Sorter
Accusort line scanners and omni-directional scanner
Transnorm gravity chutes
Blue Arc Engineering empty carton flow racks
Steeplechase platform (WCS)
Automated Order Routing Software (WCS)

Growing sales accompanied by growing labor for order fulfillment
Melaleuca's existing order fulfillment was inefficient. Their Pick to Light system required each associate to handle every container even if there were no products to be picked in that area (Pick & Pass)

The system helped Melaleuca support their 8% annual growth rate
The tri-lane pick modules directed the containers entering a zone to only those that needed product from that zone which increases efficiency for the operators
Pick to Display technology allows the employee to compare the product being picked to the displayed image of the required product. This ensures the highest level of accuracy when fulfilling customer orders