Case Studies BHFO worked with Bastian to install a perfect pick system to speed up order fulfillment

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	BHFO worked with Bastian to install a perfect pick system to speed up order fulfillment

BHFO worked with Bastian to install a perfect pick system to speed up order fulfillment

Technology Category	Automation & Control - Human Machine Interface (HMI) Functional Applications - Remote Monitoring & Control Systems Functional Applications - Warehouse Management Systems (WMS)
Applicable Industries	E-Commerce Retail
Applicable Functions	Logistics & Transportation Warehouse & Inventory Management
Use Cases	Inventory Management Supply Chain Visibility Warehouse Automation
Services	Software Design & Engineering Services System Integration
Challenge	BHFO faced several challenges in their order fulfillment process. They aimed to meet the goal of same-day shipping instead of the existing two-day shipping. Additionally, they needed to increase the picking rate to 250 items per person hour while reducing overall labor requirements. Another significant challenge was to increase throughput with a smaller system footprint and reduce the number of picking errors. Furthermore, BHFO needed an efficient way to manage millions of small SKU lots, which was becoming increasingly difficult with their existing system. Read More
About Customer	BHFO is a leading e-commerce retailer specializing in fashion and accessories. They operate a high-volume warehouse that handles millions of small SKU lots. The company is committed to providing fast and accurate order fulfillment to maintain high customer satisfaction. BHFO's business model relies heavily on efficient warehouse operations to meet the demands of their online marketplace, including platforms like eBay. With a goal to scale their operations and improve efficiency, BHFO sought advanced technological solutions to streamline their order fulfillment process. Read More
Solution	To address these challenges, BHFO collaborated with Bastian Solutions to implement a comprehensive warehouse automation system. The solution included the installation of four aisles of Perfect Pick, a goods-to-person storage and retrieval system, with five robots per aisle. This system was designed to speed up the picking process and reduce errors. Additionally, 440 feet of ZiPline conveyor were installed, featuring various types of zero pressure, DC powered conveyors, including RZPDC, BZPDC, and RZCDC. These conveyors facilitated smooth and efficient movement of goods within the warehouse. The system was integrated with a PC/PLC based human machine interface (HMI) and the Exacta warehouse control system (WCS), which worked in conjunction with the RetailOps warehouse management system (WMS). This integration ensured seamless coordination between different components of the warehouse automation system, enhancing overall efficiency and accuracy. Read More Log in to view content
Contents

Technology Category

Automation & Control - Human Machine Interface (HMI)

Functional Applications - Remote Monitoring & Control Systems

Functional Applications - Warehouse Management Systems (WMS)

Applicable Industries

E-Commerce

Retail

Applicable Functions

Logistics & Transportation

Warehouse & Inventory Management

Use Cases

Inventory Management

Supply Chain Visibility

Warehouse Automation

Services

Software Design & Engineering Services

System Integration

Challenge

BHFO faced several challenges in their order fulfillment process. They aimed to meet the goal of same-day shipping instead of the existing two-day shipping. Additionally, they needed to increase the picking rate to 250 items per person hour while reducing overall labor requirements. Another significant challenge was to increase throughput with a smaller system footprint and reduce the number of picking errors. Furthermore, BHFO needed an efficient way to manage millions of small SKU lots, which was becoming increasingly difficult with their existing system.

About Customer

BHFO is a leading e-commerce retailer specializing in fashion and accessories. They operate a high-volume warehouse that handles millions of small SKU lots. The company is committed to providing fast and accurate order fulfillment to maintain high customer satisfaction. BHFO's business model relies heavily on efficient warehouse operations to meet the demands of their online marketplace, including platforms like eBay. With a goal to scale their operations and improve efficiency, BHFO sought advanced technological solutions to streamline their order fulfillment process.

Solution

To address these challenges, BHFO collaborated with Bastian Solutions to implement a comprehensive warehouse automation system. The solution included the installation of four aisles of Perfect Pick, a goods-to-person storage and retrieval system, with five robots per aisle. This system was designed to speed up the picking process and reduce errors. Additionally, 440 feet of ZiPline conveyor were installed, featuring various types of zero pressure, DC powered conveyors, including RZPDC, BZPDC, and RZCDC. These conveyors facilitated smooth and efficient movement of goods within the warehouse. The system was integrated with a PC/PLC based human machine interface (HMI) and the Exacta warehouse control system (WCS), which worked in conjunction with the RetailOps warehouse management system (WMS). This integration ensured seamless coordination between different components of the warehouse automation system, enhancing overall efficiency and accuracy.

Impact #1	97% of orders were shipped within 24 hours, significantly improving customer satisfaction.
Impact #2	The picking error rate was improved by 90%, ensuring higher accuracy in order fulfillment.
Impact #3	The system achieved a picking rate of 320 items per person hour on the first day of operation, surpassing the initial goal.

Impact #1

97% of orders were shipped within 24 hours, significantly improving customer satisfaction.

Impact #2

The picking error rate was improved by 90%, ensuring higher accuracy in order fulfillment.

Impact #3

The system achieved a picking rate of 320 items per person hour on the first day of operation, surpassing the initial goal.

Benefit #1	97% of orders shipped within 24 hours.
Benefit #2	Picking error rate improved by 90%.
Benefit #3	320 items picked per person hour on the first day.

Benefit #1

97% of orders shipped within 24 hours.

Benefit #2

Picking error rate improved by 90%.

Benefit #3

320 items picked per person hour on the first day.

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Overview

BHFO worked with Bastian to install a perfect pick system to speed up order fulfillment

Operational Impact

Quantitative Benefit