Avoid Fulfillment Woes

The review also analyzed the operation itself, focusing on warehouse layout, flow and processes. The following recommendations, which were implemented by the marketer, emerged from the review:
1. Create a hot-pick area for the fastest-selling or “A” items.
2. Expand and/or modify the area for picking and packing ship-alone items.
3. Start peak hiring and training three weeks earlier in the season. This practice allowed the client to run a full, second shift instead of the previous one-and-a-half shift schedule.
4. Make minor changes, based on sales velocity, to the pick line layout. It increased the pick slot sizes for selected items, improving picking and replenishment functions.
5. Re-slot faster-selling items closer to takeaway conveyors. It reduced pickers’ walking times.
6. Use off-site storage for excess/reserve inventory. This process improved on-site buffer inventory efficiency and ensured that the limited, on-site space held correct items for pick-slot replenishment.