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