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automated warehouse customer repair clinic increasing efficiency by batch processing orders

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Rethinking for growth

Increased efficiency with room to grow at The Repair Clinic

• Packing/ manifest process had an unbalanced amount of labor for the pick process

• Constraint and spatial limitations within the packing area

• Mapped new process, automating repetitive tasks, and isolating special orders

• Recovered valuable space and reduced labor pain points

• System capacity almost doubled in volume

• Savings of $660,000

Bottlenecks slowing the packing process

No Space for Growth

ISD was challenged with optimizing the packing and manifesting process at The Repair Clinic.  Considerations were current inefficiencies defined by a disproportionate labor requirement compared to the picking process. Additionally, ISD needed to address the bottleneck and spatial limitations in the packing area. This prevented the company’s ability to scale alongside its double-digit growth rate.

While competitors aimed to expand through increased workstations and reduced storage for more pack stations or mezzanine additions, this would potentially double their packing workforce to 52. The Repair Clinic adopted for a different strategy.

More workstations needed

Consolidating workstations in the shipping and packaging zones decreased traffic and created additional space for future expansion.

Bottlenecks in packing

Automated repetitive, uncomplicated tasks, managed exception orders independently from the core order group, and significantly reduced labor requirements.

Create space and simplify process

Combine workstations versus replicating and enlarging the existing packing process

Create an operations master plan

ISD’s approach involved conducting a comprehensive analysis encompassing Repair Clinic’s customer order profiles, inventory dynamics, spatial utilization, and detailed assessments of employee roles, productivity, and associated expenses. The resulting plan would significantly reduce labor, reclaim valuable space and increase overall system capacity. 

Automate repetitive tasks

Unequal distribution of labor for picking and packing

Automating redundant, straightforward tasks while managing exception orders separately from the core order group, resulted in a significant reduction in labor. The new system surpassed the business’s production capacity, handling a volume higher than the company could produce, while simultaneously improving accuracy levels.

System renderings – real data

Technology and layout analysis

Our initial step involved conducting a comprehensive analysis encompassing Repair Clinic’s customer order profiles, inventory flow and spatial data, along with evaluating current technology, employee roles, performances, and associated expenses.  With solid data on worker productivity, throughput, inventory capacity and accessibility, ISD presented a plan featuring visual representations and system renderings.

Real results

System capacity doubled capability

Exceptional Operational Savings Achieved Through Enhanced Efficiency and Expansion Capability

  • Labor requirements reduced by 65%
  • 30% floor space recovered
  • System capacity doubled
  • Labor reduced by half on shipping docks
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