2. Portfolio Contents
• Summary of Major Accomplishments
• Detail of Major Accomplishments
• Page detail of each major project
• Minor Projects with Summary of Each
• List of Managed Vendors and Integrators
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3. Summary of Major Projects
• Innotrac Grove City Closure
• Rolled 388,000 sq.ft. FC into 280,000 sq. ft. of existing FC while maintaining
100% operational status - $2.0 million
• T. Marzetti Global Waste Reduction Program
• By running projects in 14 facilities, reduced raw material and labor shrinkage costs
moving average by 1.5% across six years – average of $1.75 million annually
• Staples NAD KIVA Pick and Pack system
• Managed design specification and SOP’s for KIVA robot implementation at
Quill in Chambersburg, PA - $3.5 million
• Newell Rubbermaid
• Rolled 230,000 sq. ft. of product at 3PL back into existing 1.2 million sq. ft.
and adding 330,000 sq. ft. of new product to same while maintaining 100%
operational status- $5.2 million
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4. Innotrac Grove City Closure
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Condensed 388,000 sq. ft. into 283,000 sq. ft.
5. • Location: from Grove City, Ohio to Groveport, Ohio
• Purpose: recover $4.2 million annually in FC Operations to reduce
operating costs.
• Product: Textiles, durable goods, and food supplements
• Volume profile: Seasonal e-commerce with a distinct Pareto distribution –
3,780 SKU’s, 45,000 orders per day, 4.5 line items average per order with lot
control
• Solution: Brownfield project condensed 388,000 sq. ft. into 283,000 sq. ft.
existing operation while maintaining 100% operational status. Used Very
Narrow Aisle (VNA) single select racking six levels high to create 14,000 PP
(6,000 more than in existing facility). Forward pick area and returns placed
in pick module and product picked in batch to recover 35% labor. Medium
movers placed in pallet flow. 37% of product shipped in kits. Kitting area
added. Packing done using Put-to-Light system fed by NBS30 pop-up
sorters. Product shipped using sliding shoe sorter at 80 cartons per minute.
Used Pyramid WCS with Manhattan WMOS. Designed all components:
electrical, conveyor, racking, lift truck, PTL, sorters, mezzanine.
• Completed with total costs at $2 million in six months. Payback was
$350,000 per month.
Innotrac Grove City Closure
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6. Innotrac Grove City Closure
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Partial overview of put-to-light sorters
for packing. NBS30 bi-directional
pop-up divert rollers are yellow.
Packing used air pillows when
required. Some product shipped freely.
7. Innotrac Grove City Closure
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Put Side – sort to lightPack Side – pick to light
8. • Location: Various across US.
• Purpose: Reduced net operating costs by 1% annually.
• Product: Perishable consumer goods (dressings, dips, sauces, bread)
• Volume profile: Consistent batch manufacturing and distribution– 1,628
SKU’s, 185 orders per day, 1 line item average per order, 1,428 cases per
line average.
• Solution: Annual waste was determined to exceed $8 million company-
wide through shrinkage as well as under-utilization. The actual physical
waste was measured as great as 32% in pounds, cycles, labor hours, etc. By
implementing at least five projects per facility to address the waste drivers,
the company as able to do the following:
• Reduce net operating cost by 1.5% ($1.75 million annually)
• Increase volume by 1,540 cases daily (.58% or $27,970 per day)
• Reduce total lead time (order to cash) by five days
• Reduce labor by .25%
• Increase yield by .526%
• Completed with total costs of $2,800 over twelve months.
T. Marzetti Global Waste Reduction Program
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9. • Location: Chambersburg, PA
• Purpose: recover 45% labor, improve accuracy to 9.99%, and
reduce lead times by 50%.
• Product: Durable office goods
• Volume profile: Seasonal e-commerce and B2B with a steep
distribution – 6,800 SKU’s, 32,000 orders per day, 8.2 line items
average per order.
• Solution: This project was the initial pilot project of 30 robots
in 50,000 sq. ft. The company has since expanded to 500
robots in 140,000 sq. ft. Implemented the robots with 600
pods and eighteen pack stations. Lines per hour jumped 150
to 400 in a matter of three months. Wrote the SOP’s and
training for these units.
• Completed with total costs at $3.5 million in eleven months.
Staples, NAD KIVA Pick and Pack
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10. Staples, NAD KIVA Pick and Pack
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KIVA RobotTypical picking area
11. • Location: from Manitowoc, WI to Lancaster, OH
• Purpose: reduce net operating costs for durable consumer goods
division by 28% while maintaining 100% operational status.
• Product: Durable consumer goods (glassware and cookware)
• Volume profile: Direct to Store and Distributor at 8,000 orders per
day, mostly FTL. Full case picking. 4,200 SKU’s, 28 lines per order.
• Solution: This brownfield/greenfield project consolidated 330,000
sq. ft. of full pallet storage into an existing 1.2 million sq. ft. facility,
and also 280,000 sq. ft. of 3PL storage into the same. Removed all
existing rack (drive-in racking), changed pallet stacking models to a
more supportive design, and used a mix of forward pallet flow pick,
case pick, and bulk stack to increase the density without increasing
damage. Assisted in moved manufacturing operations to newly built
Maquiladora facility in Nuevo Laredo, MX.
• Completed with total distribution costs at $1.2 million over eight
months, with a projected savings of $450,000 per month.
Anchor Hocking/Mirro Wearever
Consolidation (Newell Rubbermaid)
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12. • Location: Wareham, Massachusetts
• Purpose: to increase throughput capacity for crouton division
by 125% while maintaining 100% operational status, at no
extra operating cost.
• Product: Croutons
• Volume profile: Direct to Distributor at 590 orders per day at
1,000 lbs. per order, mostly FTL/Full Pallet. 28 SKU’s, 3.5 lines
per order.
• Solution: This brownfield project consisted of redesigning the
mixing, proofing, and baking process for 59,000 lbs. of
croutons per day. Added one new mixer and redesigned one,
replaced continuous oven, added new holding bins and
redesigned proofing room.
• Completed with total costs at $13.2 million in 16 months.
T. Marzetti Crouton Process Redesign
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14. Summary of Minor Projects
• T. Marzetti Cook Kitchen and Spice Blending Redesign, Milpitas, CA
• Redesigned 7,600 sq. ft. layout and process of seven 200 gallon cook and
blend kitchen stations and Spice Blending room using lean methodology.
Added automated lift systems to bring product to tanks. – $.82 mil
• Staples NAD Detroit Cross Dock Redesign (u/c Vargo)
• Redesigned 42,000 sq. ft. brownfield cross dock in Detroit, MI to double
throughput – $.165 mil
• KMH (Kalida Manufacturing Honda), Ottawa, Ohio (Vargo)
• Designed and implemented 80,000 sq. ft. Drive-in rack design for
automotive parts - $1.6 million
• Abercrombie & Fitch Greenfield, New Albany, OH
• Oversaw rack and mezzanine design and installation, assisted in design of
Direct to Store conveyor system- $1.8 million
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