A National Ecommerce Company

Optimized packing stations boost bottom line

The Challenge

A major American e-commerce company that sells just about everything for the home was having a big problem with preparing items to ship. Their parcel pack out area could not keep pace with demand during the holiday rush, jeopardizing their brand promise of fast, 2-day shipping. They approached us with a request to add 36 packing stations, nearly double their current number. BGR was happy to fill their order, but we wanted to be sure that adding tables would solve the long-term challenges for this rapidly-growing company.

Our Custom Solution

BGR visited their warehouse and mapped their current process, which revealed the position of the boxes and packaging materials required employees to walk around the table and step away from the table to get supplies. We provided a custom-designed BOSTONtec® Workstation that put everything at their fingertips. By changing the layout, not the tasks, we minimized material touches, motion, and effort required. They were so impressed with the efficiency they ordered 36 newly-designed tables, adding additional capacity to the facility without doubling the packing stations.

By choosing BGR to review and provide a solution, the customer estimates a cost avoidance between $500,000 and $1.5 million

The Impact for Our Client

Redesigning the stations increased both the pack out area capacity and the value of the fulfillment center by 15 - 20%. This custom solution resonated throughout the organization, and these new tables are now the standard at all of the new fulfillment centers in North America. By choosing BGR to review and provide a solution, the customer estimates a cost avoidance between $500,000 and $1.5 million and is now positioned to meet the demands of today’s consumer and meet their 2-day shipping promise.