Case Study: Melaleuca
About Melaleuca
Melaleuca is an international manufacturer of unique health, home, and personal care products. Melaleuca's growing sales accompanied by growing labor was thier main problem for order fulfillment. Their existing order fulfillment was inefficient. Their existing Pick To Light (PTL) system required each associate to handle every container even if there were no products to be picked in that area (pick & pass).
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Business Challange
- 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).
Key Technologies
- 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)
Results
- 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.
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