MAC Direct, an independent mail fulfillment house, began bursting at the seams years ago. Large new contracts were straining the ability of the New Castle, Del., facility to move orders through on time with the desired efficiency. So MAC Direct was reluctantly contemplating adding major new facilities to its 100,000 square foot warehouse to handle the increasing volume.

A full line materials handling equipment supplier was called in to offer its ideas on dealing with the higher demand. Working under tight time constraints, the supplier responded with a package of different solutions.

Under the systems concept chosen for MAC Direct, the warehouse was transformed from inefficient bulk storage to full utilization of the cubic space with 20-foot-high racking. Selective pallet storage racks increased space utilization.

The combination of an overall systems concept, equipment to match the concept, and training on how to best utilize the system has produced dramatic results. Included are maximum use of air and floor space; improved throughput efficiency; selectivity of loads, yielding one-time handling; faster, on-time order fill; and improved safety.

"The systems concept is a real winner," says Andy Fayer, warehouse supervisor. "Instead of just adding racks and a couple of forklifts," he adds, the supplier "showed us how to basically redesign our whole setup." That included "determining where items are stored, arranging efficient flow of product and vehicles, achieving one-time order handling, maximizing use of space available, and improving our ability to manage the whole operation.

"These improvements," Fayer continues, "have made a real difference in our efficiency, profitability, and our ability to deliver rapid fulfillment."

MHS Lift
888-543-8878
www.mhslift.com