Virginia Department of Alcoholic Beverage Control Case Study

Bastian Solutions Provides A Spirited Solution to VA ABC

The Virginia Department of Alcoholic Beverage Control (VA ABC) controls the sale and distribution of alcoholic beverages in the Commonwealth of Virginia. VA ABC provides service to over 300 retail outlets and is a major source of revenue for the Commonwealth.

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Business Objectives

Unprecedented growth in retail stores; difficult to meet customer demands
SKU's carried grew from 2,200 to over 3,500
Warehouse space was running low
Current facility had no automation

Key Technologies

Three 2-level pick modules for full case picking
Shoe Sorter at 450 ft/min and 100 cartons per minute throughput
Eight after sort accumulating decline spirals
Ergonomically designed de-palletization area for high volume movers
Exacta warehouse control system with automated order routing
- Interface to VA ABC host system
- Wave build system with wave label printing logic
- List picking system in each bottle area
- Quality check and exception handling module

Results

VA ABC was able to sustain a single shift operation and execute all orders within a 5-day work week.
Up to 20,000 cases could be shipped in an 8-hour day.
VA ABC has maintained 97% of the items in stock in their retail stores and is now setting its goal at a 98% “in stock” rate for all SKUs.
Improved order accuracy for retail store deliveries.
Worker's environment has been measurably better due to superior ergonomic design.