Putting all of the cube to work

Multi-level mezzanines and vertical reciprocating conveyors manage product overflow at a Lands' End distribution center.

By -- Modern Materials Handling, 12/1/2000

Business is booming at Lands' End, the second-largest mail order apparel merchant in the world. Last year, they shipped over $1.37 billion worth of cashmere sweaters, corduroy trousers, luggage, and other merchandise. About one-third of the merchandise shipped to U.S. customers leaves from their Reedsburg, Wisconsin distribution center.

When the facility was originally built in the early '90s, it was only 500,000 sq. ft. Now there is an additional 400,000 sq. ft. of space to cope with its growth in traditional catalog orders as well the debut of its Internet business, which exceeded $61 million last year.

To make maximum use of the facility, mezzanines were brought in to use vertical space. About 10,000 sq. ft. of mezzanine was installed at the facility. Making better use of the cube gave Lands' End extra room for storage of soft goods, and, in particular, clothing. The mezzanines are not just used for storage, but for orderpicking too.

A major benefit of the mezzanines, besides providing the much needed space, is that they allow greater accessibility to storage, says Kevin Unbehaun, facilities manager. It is easier for workers to access the products they need in an efficient and speedy manner. He adds that Lands' End is able to accommodate additional product.

In addition, three vertical reciprocating conveyors (VRC) were installed to provide quick, safe access to the mezzanines, and efficiently transport inventory between levels. The VRCs are centrally located to maximize movement of inventory on the floor.

"Two service structural mezzanines, and one of those two handles all of our inbound return processing. The third VRC services the third level and is being used in lieu of a conveyor," says Unbehaun, facilities manager.

"We now operate a three-level system...with the ground floor and four mezzanine structures, each with two levels," he adds.

The addition of the mezzanines and VRCs has opened up a whole new world of storage space, allowing the distribution center to keep pace with the business.

"We now have the ability to keep up with current demands while still having plenty of expansion room for the future," says Unbehaun. Additional mezzanines and VRC systems may be in the works as the company prepares for further space enhancements to accommodate even more orders as the company continues to grow.
Wildeck
262-549-4000
www.wildeck.com