Case Study
WIX Filters, a leading manufacturer of filtration products, required a modernized facility to support rapid growth and evolving demand. To optimize its 326,000 sq. ft. space, WIX Filters partnered with LD Systems to redesign its storage and order processing layout, ultimately enhancing productivity and reducing order cycle times.
WIX Filters, renowned for high quality filtration products, supplies a broad range of customers and industries. As demand increased, WIX Filters needed an upgraded distribution network to enhance efficiency and accuracy, ensuring fast and precise order fulfillment.
Facing a substantial uptick in order volume, WIX Filters sought an innovative solution to maximize storage and streamline order processing. Managing thousands of SKUs in the expansive 326,000 sq. ft. warehouse required precise handling to meet demand while reducing order cycle times. WIX Filters engaged LD Systems to lead a complete system overhaul, including storage layout optimization, high-efficiency equipment, and comprehensive project management to achieve smooth and rapid implementation.
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With LD Systems’ expertly designed system, WIX Filters realized a 400% increase in product facings, boosted productivity by 60%, and reduced order cycle time by two thirds. These enhancements allowed WIX Filters to handle increased order volumes swiftly and accurately, improving service levels for its diverse customer base.
LD Systems conducted a detailed assessment of WIX Filters’ operational bottlenecks and established a plan to streamline workflows and enhance productivity.
Leveraging advanced AutoCAD software, LD Systems crafted a layout maximizing floor space and product accessibility, integrating high-density storage and efficient pathways to accelerate order processing.
LD Systems provided custom equipment suited to WIX Filters’ specific needs and managed installation. The equipment enhanced throughput while reducing the need for manual handling.
From initial planning through final implementation, LD Systems managed each project phase, adhering to strict timelines and budgetary goals to ensure a seamless upgrade.
LD Systems developed an integrated system for WIX Filters’ 326,000-square-foot distribution center to enhance productivity and efficiency in response to rising demand. Following a comprehensive review of WIX Filters’ existing workflows, LD Systems designed a custom layout that included specialized picking zones, automated conveyor systems, and precise sorting mechanisms. Every aspect of the system was optimized to facilitate a seamless flow of products from picking to shipping, reducing manual handling time and improving order accuracy.
To maximize storage and streamline product retrieval, LD Systems installed advanced pallet and carton flow racks, ensuring rapid access to thousands of SKUs. This innovative solution significantly transformed WIX Filters’ operational capacity, enabling the facility to handle high order volumes with improved productivity and reduced cycle times.
LD Systems implemented a range of advanced storage solutions:
3-Order Selection Modules: Configured for efficient case and unit picking, reducing processing time.
Pallet Racking: High-density storage to accommodate bulk inventory and facilitate quick access.
Carton Flow: Gravity-driven racks for fast carton movement and ease of selection.
Pallet Flow: Ensures efficient first-in, first-out handling for high-demand products
The conveyor system designed by LD Systems supports efficient material handling across the facility:
Transport Conveyors: Move items between picking, packing, and shipping, minimizing manual labor.
Accumulation Points: Temporarily hold items to optimize order processing flow.
Merges: Consolidate multiple SKU lines for streamlined organization.
Sorter: Directs items to designated zones for improved sorting accuracy.
Controls and Weight Verification: Verifies item weight and flow, ensuring precision before shipping.
LD Systems’ integrated solution has transformed WIX Filters’ distribution center, enabling it to keep pace with rising demand while enhancing speed and accuracy. With improvements in product facings, productivity, and cycle time, WIX Filters is now positioned to deliver exceptional service, meeting the needs of a rapidly growing customer base.
