140 Years of Quality Electrical Tools Hits the Fast Lane
Greenlee
System Overview:
For more information, visit bastiansolutions.com or call (800) 772-0464
Greenlee is known for its high quality tools used in the electrical construction trade, including all types of hand tools, hole making tools, cable pullers, wire terminators, and testing and measurement equip-ment. Greenlee’s Rockford, IL distribution center was constrained at 90,000 sq. ft. and had several opera-tional problems including very manual, inefficient processes. Because labor costs were so high, they decided to relocate to Southaven, MS. With Bastian’s expertise, Greenlee was able to significantly increase picking productivity and reduce total labor headcount by 35%.
System Overview:
140 Years of Quality Electrical Tools Hits the Fast Lane
Greenlee
For more information, visit bastiansolutions.com or call (800) 772-0464
Business Challenges:• The existing Rockford, IL distribution center was space
constrained at 90,000 sq. ft. and had several operational
problems including very manual, inefficient processes
• The cost to operate the facility was very high due to
union wages and excessive overtime
• The facility had to cut off its daily shipping at 3pm in or-
der to meet early pick-up times for Fedex trucks deliver-
ing shipments to the Chicago hub
• To reduce labor costs Greenlee decided to relocate the
distribution operation to Southaven, MS, just 10 miles
from Fedex’s largest air terminal
Key Technologies:• Unarco 3-level pick module with a zone pick conveyor
system
• Unarco racking
• Hytrol ABEZ conveyor
• Best Expanding Dock conveyor
• Accu-sort scanners
• ASAP Warehouse Control System (WCS)
• Mettler-Toledo Scales
• Symbol RF handheld picking devices
• SAP ERP interface
Results:• Bastian’s solution increased picking productivity signifi-
cantly and met Greenlee’s productivity goals
• The new Distribution Center in Southaven leaves Green-
lee well-positioned for growth
• Greenlee was able to reduce total labor headcount by
35% by reducing their 3-shift operation to a two-shift
operation