One of America’s largest warehouse clubs needed to streamline operations at its new cross-docking facilities. By installing WPSS Put Wall integrated with a customer-supplied Pick-to-Light system, the club increased pick rate productivity by approximately 40%, achieving leaner workflows and superior sorting accuracy.
The Challenge: High-Speed Cross-Docking Needs Efficient Sorting
A leading American warehouse club relies heavily on cross-docking – a logistics strategy where incoming shipments are transferred directly to outbound transportation, bypassing long-term storage. With new distribution centers opening in Texas and California, the club needed a system to handle the rapid flow of goods.
Key Requirements:
- Throughput Speed: The system had to support a high-volume environment where speed is critical.
- Sorting Accuracy: Efficiently sorting goods from receiving to shipping required a specialized infrastructure.
- Pass-Thru Design: The ideal solution needed to allow stocking from one side and picking from the other to prevent congestion and streamline workflows.
The Solution: Put Wall
The warehouse club selected Western Pacific Storage Solutions (WPSS) to provide the infrastructure for their optimized pick-and-pack operation. The solution centered on the Deluxe Industrial Shelving line, configured specifically as Put Wall.
Designed for Speed and Integration
- Integrated Technology: The shelving was designed to seamlessly integrate with a Pick-to-Light / Put-to-Light system (supplied by the customer’s choice vendor). This technology directs operators to the exact location and quantity for each order, drastically reducing errors.
- Pass-Thru Efficiency: The pass-through design separates stocking and picking aisles, allowing simultaneous activity without interference.
- Robust Construction: Built with box posts at the corners, the deluxe shelving offered the rigidity and stability needed to handle heavy daily use.
- Scalability: At the California location alone, units were joined to create continuous picking walls spanning 70-80 feet, with individual units subdivided into cubbies for precise sorting.
Results: 40% Increase in Productivity
The installation was a resounding success, completed in less than two weeks without operational hiccups.
| Outcome | Benefit to Client |
| 40% Productivity Boost | The combination of pass-thru design and light-directed technology increased pick rates by approximately 40% compared to manual methods. |
| Lean Operations | The system facilitated a smoother, faster flow of goods from receiving to shipping, cutting out unnecessary handling steps. |
| Rapid Deployment | The WPSS team executed a seamless installation, allowing the facility to ramp up operations quickly. |
| Repeat Success | Satisfied with the streamlined throughput, the club has already purchased additional Put Wall systems for their newest facility. |
By investing in Put Wall, the warehouse club successfully optimized its cross-docking strategy, ensuring that its supply chain remains as fast and efficient as its business model demands. Ready to work on your next project? Big or small, WPSS has experts ready to assist! We provide layout guidance, spec sheets, and recommend best-practice clearances to ensure an efficient and space saving design. Contact us today for a quote.