Greenlee

Order Picking Automation Solution

Business Objectives

  • The existing Rockford, IL distribution center was space constrained at 90,000 sq. ft. and had several operational problems including very manual, inefficient processes
  • The cost to operate the facility was very high due to union wages and excessive overtime
  • The facility had to cut off its daily shipping at 3pm in order to meet early pick-up times for Fedex trucks delivering shipments to the Chicago hub
  • To reduce labor costs Greenlee decided to relocate the distribution operation to Southaven, MS, just 10 miles from Fedex's largest air terminal
Greenlee System Illustration Header

140 Years of Quality, Electrical Tools Hits the Fast Lane

Greenlee is known for its high quality tools used in the electrical construction trade, including all types of hand tools, hole making tools, cable pullers, wire terminators, and testing and measurement equipment.

Greenlee's Rockford, IL distribution center was constrained at 90,000 sq. ft. and had several operational problems including very manual, inefficient processes. Because labor costs were so high, they decided to relocate to Southaven, MS. With Bastian's expertise, Greenlee was able to significantly increase picking productivity and reduce total labor headcount by 35%.

Greenlee System Illustration
 

Key Technologies

 

See the results

Bastian Solutions's effort increased picking productivity significantly and met Greenlee's productivity goals.

The new Distribution Center in Southaven leaves Greenlee well-positioned for growth

Greenlee was able to reduce total labor headcount by 35% by reducing their 3-shift operation to a two-shift operation

 

Photos of our solution

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