Case Study
As WIX Filters continued to grow, their distribution center needed significant upgrades to manage the increased demand efficiently. Handling a wide range of products, they required solutions to expand product facings, reduce order cycle times, and improve productivity.
Founded in 1939, WIX Filters is a leading manufacturer specializing in filtration products, with applications across automotive, industrial, and agricultural industries. As a major supplier in North America, WIX Filters distributes from its 326,000-squarefoot warehouse, requiring a robust, high-efficiency solution to handle expanding product lines.
WIX Filters’ expanding operations placed pressure on its existing distribution network, which needed to scale efficiently without sacrificing productivity. With over 326,000 square feet of warehouse space and multiple SKU categories, WIX Filters sought a system to support rapid order processing and improved workflow efficiency. To lead the transformation, WIX Filters partnered with LD Systems, which delivered comprehensive material handling and layout solutions.
LD Systems designed and implemented an integrated solution that optimized the distribution center’s layout and introduced advanced material handling systems. This transformation enabled a 400% increase in product facings and a 70% productivity boost while reducing order cycle times by two-thirds. With streamlined picking and storage capabilities, WIX Filters can now meet customer demands swiftly and with greater accuracy.
LD Systems conducted an in-depth assessment of WIX Filters’ existing workflows to identify areas for improvement. This review allowed for a customized strategy that aligned with WIX’s goals for improved efficiency and throughput.
The layout was meticulously planned in AutoCAD to maximize space usage and reduce unnecessary movements. The design included optimized pathways and strategically placed picking and sorting areas, ensuring smooth product flow throughout the facility.
High-performance equipment tailored to WIX Filters’ operational needs was carefully selected and installed, enhancing throughput and accuracy across the warehouse. LD Systems managed each phase of the installation, from setup to testing, ensuring optimal performance and minimal disruption.
LD Systems provided end-to-end project management, overseeing each stage from concept to completion. Their management ensured timelines and budgets were met, delivering a seamless transition to the new distribution network.
LD Systems designed an integrated system for WIX Filters’ 326,000-square-foot distribution center to accommodate growing demand. Following an operational analysis, LD Systems developed a layout that included dedicated picking modules, optimized conveyor pathways, and efficient sorting systems, ensuring a streamlined flow from picking to shipping. To maximize space and retrieval speed, LD Systems implemented advanced pallet flow racks and carton flow racks, making SKUs accessible and reducing handling time. This solution transformed WIX Filters’ operational capacity, resulting in faster order processing and improved productivity.
LD Systems introduced a range of advanced storage options, including:
Pick Modules: Configured for high-speed selection, streamlining workflows across picking zones.
Pallet Flow Racking: Designed for high-density storage, maximizing the volume of palletized products.
Carton Flow Rack: Gravity-fed racks expedite item selection from loading to picking stations.
Finger Aisles: Strategically placed to enhance access and reduce travel time within the facility.
A modern conveyor system supports WIX Filters’ high-efficiency material movement:
Transport Conveyors: Facilitate smooth movement between picking, packing, and shipping zones.
2 to 1 Merge: Consolidates product lines for streamlined sorting and packing.
MDR Conveyor: Provides modular control for faster and more efficient item flow.
Spiral Conveyor: Optimizes vertical transport for multi-level facilities, reducing travel time.
With LD Systems’ comprehensive solution, WIX Filters’ distribution center now operates at peak efficiency, supporting high demand and achieving enhanced accuracy. The new system allows WIX Filters to continue its growth while providing reliable, timely service to its customers.
