New DC solves the challenges of growth

A custom fleet of lift trucks maximizes efficiencies.

Modern Materials Handling - October 2, 2006

When California-based clothing manufacturer Jerry Leigh Inc. planned its move from a 10,000-square-foot DC to an 80,000-square-foot facility, the focus was entirely on efficiency.

The company, which makes and distributes licensed apparel and accessories for brands such as Disney, Nickelodeon, Warner Bros. and Marvel, started with a custom-designed rack and shelving system to store inventory. But, it didn't stop there.

To get the most out of the new DC, the company purchased a diverse fleet of new lift trucks, including reach trucks, order pickers, electric walkie pallet trucks and sit down counterbalanced riders. To deal with the power requirements of these vehicles, a battery handling center was added to the facility.

The upgrade in speed and efficiency provided by the new equipment was critical. The new warehouse design and logistics strategy maximized storage space and allows DC managers to manage increased orders. Operational efficiency improved and order tracking became more detailed and accurate. The rate of inventory rotation also increased.

"Over the last decade, our resort division has experienced exponential growth with intensified order volume," says Tim Purdy, divisional vice president for Jerry Leigh. "These increases put enormous pressure on us to fulfill the mounting number of orders arriving daily."

"The aim is not only to provide faster service," says Purdy, "but to handle increased business without significantly increasing resource costs."