Houston Johnson, Inc.

ExactaWMS: Warehouse Management System Case Study

Business Challenges

  • Picking was done by labels and was more labor intensive.
  • Validation of the sequencing was very manual and challenging to track.
  • With sequencing errors an inconsistent threat, a large claims budget needed to be maintained as a safety net

Houston Johnson Sequences Key Components to Ford Plant 

Founded in 1987, Houston-Johnson provides logistic services to the largest automotive manufacturers and parts suppliers as a Tier 1 or Tier 2 supplier. These services include sequencing, modular assembly, kitting and rework operations with automotive suppliers and consumer products. With high labor costs, manual processes and low system visibility, HJI was looking for a change. HJI selected the ExactaWMS: Warehouse Management System from Bastian Solutions.

*Video Note: ASAP Automation is now Bastian Software Solutions


See the results

Ford receives their components on time and in the right sequence. Customer service has increased dramatically. “We are giving customers the visibility they want and need to make timely decisions”, says Daniels.

Decreased labor costs. The WMS has decreased the manpower needed to perform the same processes.

Increased throughput over 50%. “Our growth in our sequencing business from 1 contract to 9 since implementing Exacta is a testament in itself!" says Daniels.

Decreased training costs. HJI is able to have one platform for all of their operators across the sequencing segment which allows for cross training.

Eliminated claims budget. Reduced expenses and improved use of capital funds.


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