When Eastbay, a former e-commerce supplier of athletic footwear, apparel and sports equipment (now merged with Champs Sports), decided to double the size of the current facility to over 500,000 sq. ft., they requested direction and input from three qualified system integrators. The current material handling system would require a complete redesign to handle to projected case rates of 60,000 orders per day. It was determined that a series of tote-handling conveyors and package-handling conveyors would be needed to fill the orders at the current and projected rates.
Orders are generated from the current warehouse management system and printed overnight to a paper pick ticket. The orders are placed in the pick racks for the operators. Operators then pick orders to totes and place the completed pick on one of two 300’ long live roller take-away conveyors running the width of the building. The two take-away lines incline and merge into a Hytrol high-speed 2:1 roller merge.
Learn how Eastbay significantly reduced the labor hours required during their peak production.
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