Since 1972, Woodbury Automotive Warehouse Enterprises has provided aftermarket automotive parts to independent jobbers in the tri-state area of New York, New Jersey and Connecticut. This winning partnership has given clients a competitive edge and allowed Woodbury to grow.

Woodbury's warehouse was running two shifts, seven days a week, which included e-order fulfillment through the same distribution center.

Even with adjustments to satisfy growing pains, Woodbury couldn't keep up with demand. Manual sortation systems and a cramped shipping area were further stressed by a returns area that encroached on receiving.

Woodbury incorporated materials handling techniques along with computerized order processing—keeping disruptions to a minimum while freeing up space for transformation.

First, leased space next door was redesigned to accommodate the pick-up business and returns logistics exclusively, each separated in an autonomous area connected by a walkway to the main DC.

Existing DC space was re-engineered using some new software and hardware. Storage and retrieval efficiencies were implemented and rows were shortened for faster order fulfillment, and non-conveyable bulk storage was added.

The small parts picking area was expanded and the old conveyor system was upgraded with custom controls software and new transport and merge lines were built to automate sortation of product orders. The software component is warehouse management system-ready.

Both facilities received high-efficiency lighting for a brighter workplace and cost savings projected at 30%. And because Woodbury worked through the ConEd New York energy program, they received a grant covering 15% of the installation cost.

The transformed DC and new pick-up warehouse give Woodbury the capacity to keep up with current orders and future growth.

Hy-Tek Material Handling Integrated Systems 866-856-7212 www.hy-tek.net