by Noelle Abarelli | Aug 24, 2021 | Alpine News Blog, Blog
Bongards’ Minnesota facility, which picks, packs and ships cheese to customers nationwide, was bursting at the seams. Alpine Supply Chain Solutions conducted an overall facility layout to help move product faster.
As a farmer-owned co-op since 1908, Bongards has unsurpassed cheesemaking expertise. Today, some of the biggest names in retail, foodservice and manufacturing turn to Bongards for wholesome, premium cheeses crafted to their unique specifications and sourced responsibly. Bongards has a long tradition of doing things the right way in terms of the way they service their customers and run their business. When they found its Minnesota facility, which picks, packs and ships cheese to customers nationwide, was bursting at the seams and slowing down service, they knew it was time to act.
The challenge
Growth meant it was time for a change, but Bongards was unsure whether this meant expanding to a new, larger facility or making more efficient use of its current one.
The company reached out to Conveyor Solutions Inc. (CSI), a turnkey system integrator, to begin exploring physical equipment that could help make better use of their space. CSI knew Bongards couldn’t afford to get things wrong, so they brought in Alpine Supply Chain Solutions to do a deep dive into the big picture — an overall facility layout.
“Conveyors, picking devices and sortation systems can get expensive quickly,” says Kevin Thompson, West Coast relations builder for CSI. “We really wanted to make sure Bongards had a solid understanding of their volumes and order profiles which would drive their facility layout and physical equipment needs. This is an area where Alpine really shines, and we were glad to partner with them.”
The process
Alpine began facility design by analyzing data on Bongards’ inbound and outbound shipments, inventory on hand, labor and material handling equipment to understand current business and future needs.
Alpine performed a Storage Type Analysis (STA). This exercise considers detailed SKU data, including size, shape and velocity, and assigns each SKU to its ideal storage location type based on its unique characteristics. Applying inventory rules based on individual SKU ABC categories assured the right products were assigned to the right type of pick location within the distribution center.
”Our focus was on getting product in and out of the facility with minimal touches and travel distance,” according to Michael Wohlwend, Alpine’s managing principal. “We also know that the Bongards business will continue to grow and wanted to be sure that the new layout was flexible and could handle changes, like the addition of new customers and products.”
The new layout included designated zones for bulk and broken case picking and the right sizing of the deep lane storage. Alpine also fitted Bongards with 2D, 3D and 4D push-back racking to meet Bongards storage demand.
Once the layout was complete, Alpine slotted both the broken case and full case picking areas to maximize picking efficiencies.
The outcome
The food world is moving fast. Bongards knows its customers need an uninterrupted supply of ingredients to capitalize on opportunities and win over consumers. While the team is still operating in the early phase of this initiative, productivity has been positive and efficiencies have been achieved, especially when dealing with complex orders involving multiple products. The “pick aisle” concept has proven to be a major variable enabling this improvement.
As Bongards continues to work toward streamlining processes in the mode of continuous improvement, it expects efficiency improvements to reach 20%. Pallet utilization has reached 90% with the new layout since installation of the multi-depth pushback storage solution.
See the full story on foodlogistics.com.
by Noelle Abarelli | Aug 4, 2021 | Alpine News Blog, Blog
When implementing new software into your DC, there are many potential errors that can occur, affecting your productivity and bottom line. Implementations require time, planning, and testing to ensure it all goes off without a hitch. In order to be prepared for what’s to come, it’s a good idea to familiarize yourself with some of the most common missteps. So what are some top mistakes in supply chain implementations?
- Planning and timelines
- Early alignment between operations and IT
- Demonstrable buy-in from leadership
- Training/strong user adoption
- Testing, testing, and more testing
- Change management preparation
We recently worked with our partners at made4net on a white paper titled: “ASK THE EXPERTS: What are the Top Mistakes You See in Supply Chain Solution Implementations?” This resource takes a comprehensive look at the steps one can take to ensure their success during software implementation. You can access the paper here.
If you’re short on time, we’ve included a summary below on what you can do to ensure supply chain implementation success.
Planning:
As our very own Principal, Michael Wohlwend said, “A well-developed plan can be executed to success by a team with average skills. But a poorly developed plan – or an implementation without a plan – will end in partial success at best, and failure at worst, even if the implementation team are rock stars at what they do.” Simply put, you need a comprehensive and detailed plan in order to have your implementation go smoothly, with every necessary task assigned to a resource. Most importantly, customers need to be involved with the entire process; there is no hands-off approach when it comes to software implementation.
Alignment:
Inter-departmental alignment and project understanding are key factors in ensuring success down the line. Greg Puckett of 4SIGHT Supply Chain Group said it best, “Early alignment between operations and IT that produces a clear and detailed solution design with thoroughly-defined roles and responsibilities between the client, the software vendor, and the third-party implementation partner are crucial to a project’s success.”
Buy-In:
The best way to demonstrate the importance and value of a project is to have leadership buy-in from the get-go. As Christian Nixel, Senior Director of Supply Chain Solutions for enVista says, “Top leadership has to be out front, leading and pulling the organization with them.” Continued involvement from leadership and project managers will keep the momentum going throughout implementation, while inspiring team members to put their best feet forward throughout the engagement.
Training:
Getting to know and understand how a WMS system functions takes time, practice, and patience – it’s an ongoing endeavor, and one of the most crucial aspects of any implementation. “Training is a process, and final end-user training and the education of the supervisory leads should be developed and conducted by company resources,” explains John Sidell, CEO and Managing Principal at New Course Group. It’s important for all team members to receive training, understand the software, and be prepared for whatever issue could potentially arise. Wohlwend agrees, “The trainers must train on more than standard processes; they must be trained on ‘what ifs’. How do they know when they are going off track? How should they handle issues? How do they recover from them? The trainers need to be able to run the operation with no help from day one.”
Testing:
Testing a new system is more than good practice, it’s essential. In addition, testing needs to happen multiple times to ensure nothing is missed. More importantly, tests need to be done to push the boundaries of the system, to see what would happen in a worst-case scenario setting. Puckett says that for a successful implementation, it’s necessary to perform “Full and comprehensive testing that is not compromised by a compressed or unrealistic project schedule or scope creep.”
Change Management:
Preparing the staff for change needs to happen from the start of the project, not only during training. Staffing levels, roles, responsibilities, and even pay scales can be impacted by software implementations, so it’s important to consider human resources-related changes early on to improve your chances of user adoption. “New software impacts not only the distribution center (DC), but other departments in the company, as well as customers, carriers, and suppliers,” said Sidell. Having human resources as part of your game plan will go a long way in ensuring your staff is on board and ready to learn a whole new system, without any fear or stress.
These are but a few key takeaways from “ASK THE EXPERTS: What are the Top Mistakes You See in Supply Chain Solution Implementations?” Be sure to download your copy. As always, we’re here to make sure you get the most out of your supply chain. For any questions about how we can help you with warehouse consulting, strategic planning, HR Solutions, supply chain systems, or manufacturing, reach out.
by Noelle Abarelli | Jul 26, 2021 | Alpine News Blog, Blog
Alpine Supply Chain Solutions’ New Facility Layout Empowers Bongards to Continue Meeting their Customers’ Cheese Needs
Alpine Supply Chain Solutions is thrilled to announce their new facility layout design for Bongards has led to increased productivity and better efficiency.
Bongards is a farmer-owned co-op that’s been around since 1908. They have unsurpassed cheese-making expertise, and today, some of the biggest names in retail, foodservice, and manufacturing turn to Bongards for wholesome, premium cheeses crafted to their unique specifications. Bongards has a long tradition of doing things right when it comes to servicing their customers and running their business, so when they noticed their growth was impacting their service levels, they knew they had to act.
The company reached out to Conveyor Solutions Inc. (CSI), a turnkey system integrator, to begin exploring physical equipment that could help them make better use of their space. CSI brought in Alpine Supply Chain Solutions to do a deep dive into the big picture: an overall facility layout.
“Conveyors, picking devices, and sortation systems can get expensive quickly,” says Kevin Thompson, West Coast Relations Builder for CSI. “We really wanted to make sure Bongards had a solid understanding of their volumes and order profiles which would drive their facility layout and physical equipment needs. This is an area where Alpine really shines, and we were glad to partner with them.”
Alpine analyzed Bongard’s inbound and outbound shipments, inventory on hand, available labor, and material handling equipment to understand their current business and future needs. They also performed a Storage Type Analysis (STA) to obtain detailed SKU data, including size, shape, and velocity in order to assign each SKU to its ideal storage location type based on its unique characteristics.
According to Michael Wohlwend, Alpine’s Managing Principal, ”Our focus was on getting product in and out of the facility with minimal touches and travel distance. We also know that the Bongards business will continue to grow, and wanted to be sure that the new layout was flexible and could handle changes, like the addition of new customers and products.” The new layout included designated zones for bulk and broken case picking and the right sizing of the deep lane storage. Alpine also fitted Bongards with 2D, 3D, and 4-Deep Push-Back Racking to meet Bongards’ storage demands.
While the team is still operating in the early phase of this initiative, productivity has improved and efficiencies have been achieved, especially when dealing with complex orders involving multiple products. In addition, pallet utilization has reached 90% since the installation of the multi-depth pushback storage solutions. The “pick aisle” concept has proven to be a major variable enabling all these improvements.
As Bongards continues to work towards streamlining processes in the mode of continuous improvement, they expect efficiency improvements to reach 20 percent. To learn more about how Alpine Supply Chain Solutions can help with warehouse consulting, strategic planning, HR solutions, supply chain planning, or manufacturing, visit www.AlpineSupplyChain.com.
About Alpine Supply Chain Solutions
Alpine Supply Chain Solutions, based in Chicago, IL, is a supply chain consulting company driven to ensure their clients get the most value from their investments. Their approach to every project starts with the data and ends with a cost justifiable solution. With deep roots in industrial engineering, Alpine’s approach is unique. For more information, please visit: <https://www.AlpineSupplyChain.com>.
About Conveyor Solutions, Inc.
Conveyor Solutions, Inc., as part of the Systems in Motion Group, is a turnkey system integrator that uses cutting-edge technology to design warehouse solutions and improve production. They strive to exceed customer expectations by providing innovative automation solutions, procedural improvements, flexible software, and reliable equipment. Conveyor Solutions works with all system level needs from straightforward belts to highly complex and automated warehouse redesigns. The Systems in Motion family of companies provides service at every step of the process and sources products from the most trusted manufacturers available. Learn more at: <https://www.conveyorsolutions.com/>.
About Bongards
Bongards is ready to be your trusted cheese supplier. More importantly, they’re determined to be your partner. As a farmer-owned coop with over a century of cheese-making expertise, Bongards can meet all your cheese category needs with an assured supply chain, a broad selection, and the know-how to create products to your exact specifications. Learn more at: <https://www.bongards.com/>.
by Noelle Abarelli | Jun 16, 2021 | Alpine News Blog, Blog
Alpine Supply Chain Solutions is pleased to announce that Supply & Demand Chain Executive, the only publication covering the entire global supply chain, has selected MJ Holding, the largest North American distributor of trading cards, related trading card supplies, collectibles, toys, and hot trend items, as a recipient of the Top Supply Chain Project Award for 2021. The project recognized was completed with support of Alpine and Conveyor Solutions, Inc. (CSI) – a Systems in Motion Company.
The Top Supply Chain Project (formerly known as SDCE 100) spotlights successful and innovative transformation projects that deliver bottom-line value to small, medium and large enterprises across a range of supply chain functions. These projects show how supply chain solutions and service providers help their customers and clients achieve supply chain excellence and prepare their supply chains for success.
“The supply chain industry has been challenged with a host of supply chain disruptions over the last year. Yet, the winners on this list continued to re-tool and innovate,” says Marina Mayer, editor for Supply & Demand Chain Executive and Food Logistics. “Whether it be moving a customer to a cloud-based solution or implementing a more sustainable shipping option, these top supply chain projects reflect the supply chain industry’s strength and resilience to overcome disruptions and work better, smarter and more efficiently in the years ahead.”
Over the past several years, MJ Holding has seen their retail distribution footprint across the United States and Canada explode. The company was honored for their initiative to combine multiple inventory locations into a single new warehouse that can accommodate all on-hand inventory. The company partnered with Alpine Supply Chain Solutions and Conveyor Solutions, Inc. (CSI) to design the new facility and processes. In the end, a new layout and picking process meant that MJ Holding can now pick the equivalent order volume in just 57% of the original time.
According to MJ Holding COO, Mark Zabloudil, “We’ve always prided ourselves in providing superior customer service, and the work we completed with Alpine and CSI positions us to continue doing so well into the future. It’s been an incredibly challenging year for the retail industry, and we’re truly honored to receive this commendation.”
Go to http://www.sdcexec.com to view the full list of all 2021 Top Supply Chain Projects winners.
About MJ Holdings LLC
MJ Holding is the largest North American distributor of gaming, sports, and entertainment trading cards, related trading card supplies, and hot trend items. With almost 20 years of distribution experience under their belts, MJ Holdings has developed a category management process that has enabled them to grow across the US and into Canada. For more details, visit http://www.mjholding.com.
About Alpine Supply Chain Solutions
Alpine Supply Chain Solutions, based in Chicago, IL, is a supply chain consulting company driven to ensure their clients get the most value from their investments. Their approach to every project starts with the data and ends with a cost justifiable solution. With deep roots in industrial engineering, Alpine’s approach is unique. For more information, please visit: http://www.AlpineSupplyChain.com.
About Conveyor Solutions, Inc.
Conveyor Solutions, Inc., as part of the Systems in Motion Group, is a turnkey system integrator that uses cutting-edge technology to design warehouse solutions and improve production. They strive to exceed customer expectations by providing innovative automation solutions, procedural improvements, flexible software, and reliable equipment. Conveyor Solutions works with all system level needs from straightforward belts to highly complex and automated warehouse redesigns. The Systems in Motion family of companies provides service at every step of the process and sources products from the most trusted manufacturers available. Learn more at: http://www.conveyorsolutions.com.
About Supply & Demand Chain Executive
Supply & Demand Chain Executive is the only supply chain publication covering the entire global supply chain, focusing on trucking, warehousing, packaging, procurement, risk management, professional development and more. Go to: http://www.sdcexec.com.Thanks!
by Noelle Abarelli | Jun 7, 2021 | Alpine News Blog, Blog
It’s summertime, and for all of us at Alpine Supply Chain Solutions, that means it’s our chance to mentor the next generation of supply chain leaders. We’re excited to welcome four interns this summer: Rachel Lewis, Hunter Molnar, Maddie Solomon, and Kate Wesche. Our internship program is focused on helping college students and recent graduates build connections while they learn and grow. We hope their time with us empowers them not only to achieve their goals, but to discover what their many passions may be.
During their internship, Rachel, Hunter, Maddie, and Kate will connect with one another and build community within their teams, all while engaging with senior leadership around the company for guidance and mentorship. The supply chain world is always looking for new and innovative ways to solve problems, and we’re confident that these interns are going to teach us just as much as we teach them! Here’s a little more about our interns.
Rachel Lewis
Rachel has accumulated several years of internship experience throughout her four years at Northwestern University. In June she’ll graduate with a B.S. degree in Learning and Organizational Change, and a Business Institutions minor. She has experience in a variety of industries including Consulting, Fintech, and Healthcare. During these quarter-long roles, Rachel led marketing campaign strategies, contributed to change management initiatives for areas of potential operational improvement, and built innovative solutions around specific business needs. Throughout these internships, she found a passion for using data-driven analysis to improve processes and efficiency. And that’s not all! Rachel has even led the Northwestern Softball team to three consecutive NCAA post-season appearances, a huge feat!
Hunter Molnar
Hunter is an engineering student who is deeply immersed in environmental engineering, with a technical aptitude for problem-solving, and a passion for making a change in the world. He has experience in warehouse distribution centers, where he was responsible for monitoring overall team and individual employee performance, and compiling data into project reports for the supervisor. He was also tasked with communicating with all stakeholders, including upper management, team members, and customers. Currently enrolled at Ohio State University, Hunter relishes applying CAD and MatLab to real-world problems and designing never-seen-before solutions. In Hunter’s spare time, he enjoys Buckeye football games, weightlifting, and being active in his fraternity.
Maddie Solomon
Maddie is a rising junior at the University of Kansas (KU), majoring in Marketing and Business Leadership & Management with a Certificate in Professional Selling. As a member of the business leadership program, she has had the opportunity to build and facilitate a major panel each semester for all first-year business students at KU. And as a house manager at Kappa Alpha Theta, Maddie has been responsible for managing the 100 women who live in the facility. Maddie’s wide range of experience, from organization and attention to detail, to problem-solving and leadership skills, are but a small sample of her great talents.
Kate Wesche
Kate recently graduated from Michigan State University (MSU), known for having the best-ranked undergraduate supply chain program in the nation, with a Bachelor’s Degree in Applied Engineering and Supply Chain Management. She took classes to expand her knowledge in procurement, manufacturing, logistics, and demand forecasting and also worked on many projects using Excel, Tableau, and AutoCAD. She has experience working for a consumer goods/eCommerce company where she helped them start a private label and find high-quality suppliers. She likes to see her analysis help companies find ways to reduce costs by improving production setup, eliminating the production of excess units, and lowering unneeded inventory. In her free time, Kate enjoys traveling and spending time with her friends and family.
Welcome, interns! We’re so excited to have you on board.
