Food Distributor Improves Pick Rates 52% with Optimized Material Handling
Summary
Learn how a refrigerated food distribution center redesigned their material handling equipment and workflows to dramatically improve throughput and worker safety.
Our Role
- Workflow and ergonomic assessment
- Equipment selection and procurement
- Layout optimization recommendations
- Temperature zone equipment specification
- Staff training and safety program
Client Profile
The Challenge
Pain Points
- Low pick productivity: Workers averaging 85 cases per hour vs. industry benchmark of 130
- High injury rates: 23 recordable injuries in prior year
- Equipment failures: Aging pallet jacks and carts causing downtime
- Ergonomic issues: Excessive bending, reaching, and lifting
- Temperature challenges: Equipment not rated for freezer operations
The Solution
Phase 1: Pick Cart Redesign
We implemented ergonomic pick carts with adjustable height platforms (waist-level picking), cold-rated casters (-40°F rated), enclosed bearings for freezer protection, and lightweight aluminum construction.
Phase 2: Powered Equipment Upgrade
Electric Pallet Jacks- 45 units across three facilities
- 8,000 lb capacity, cold storage rated batteries
- 12 units for cart train operations
- 15,000 lb towing capacity
Phase 3: Workstation Ergonomics
- Hydraulic pallet positioners bringing product to waist height
- Insulated floor mats for freezer areas
Results
Productivity Improvements
| Metric | Before | After | Improvement |
|---|---|---|---|
| Cases per hour | 85 | 129 | 52% increase |
| Orders per shift | 145 | 186 | 28% increase |
| Travel time | 38% of shift | 24% of shift | 37% reduction |
| Equipment downtime | 12% | 3% | 75% reduction |
Safety Improvements
| Metric | Before | After | Improvement |
|---|---|---|---|
| Recordable injuries | 23/year | 8/year | 65% reduction |
| Back injuries | 11/year | 2/year | 82% reduction |
| Workers comp costs | $380K | $125K | 67% reduction |
Financial Impact
- Labor efficiency: $425,000
- Workers comp reduction: $255,000
- Equipment maintenance: $48,000
- Total: $680,000/year (Payback: 6.9 months)
Explore Our Material Handling Solutions
Ready to optimize your material handling operations? Learn more about our offerings:
- Material Handling - Industrial workbenches, ergonomic carts, and storage systems
- Warehouse Labeling - Location identification for efficient picking
- Barcoding Equipment - Mobile computers and scanners for inventory management
Conclusion
Material handling optimization in food distribution requires understanding the unique challenges of temperature-controlled environments. By deploying cold-rated, ergonomic equipment and optimizing workflows, this distributor achieved dramatic improvements in productivity and safety.
Contact Country Innovation & Supply for a material handling assessment.
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