Modern Materials Handling’s December 2017 issue put Rocky Brands on its cover for the second time, with a walkthrough of how the manufacturer and distributor of work, western and outdoor footwear and apparel brands—including Rocky, Durango, Michelin, Georgia Boot and Mossy Oak—upgraded its 200,000-square-foot facility in Logan, Ohio. At the centerpiece of the updates, a new putwall driven by pick-to-light technology from Lightning Pick, a Matthews Automation Solutions’ brand.
The reason for the operational overhaul, explains Kevin Koster, Director of Distribution Services, in the article: “We’re doing more just-in-time shipments from customers who are ordering more often and in smaller quantities. Instead of sending three or four thousand pairs of shoes to a distribution center, we’re doing more for the stores and everything needs to be shipped in a day or two.”
With the new putwall, packing is now much faster and more accurate than the previous system. As the article explains:
When items arrive at the putwall, an associate on one side scans the UPS code of each. A light indicates the right slot in the putwall for the put. Once all the items for a slot are complete, the system prints out the shipping documentation. The associate scans a bar code on the documentation, which alerts a packer on the other side of the wall that the order is complete. The documentation also tells the packer what size box to use. Once the item has been packed and sealed, a takeaway conveyor delivers it to the shipping sorter.