SUCCESS STORIES
A global medical device manufacturer faced inefficiencies in its warehouse due to poor location utilization and complex handling requirements for batch- and serial-controlled inventory. Pickers often traveled long distances because inventory was spread across multiple locations, while inconsistent forward pick strategies created uneven labor demands. As order volumes grew, these inefficiencies made it difficult to scale operations while maintaining accuracy and compliance. The organization needed a more structured slotting approach to improve productivity and support growth.
Alpine conducted a Storage Type Analysis (STA) to redesign the warehouse slotting strategy and improve storage utilization. The team implemented clear slotting rules, including dedicated forward pick locations for batch-controlled SKUs and optimized placement for serial-controlled items to simplify execution. Multiple scenarios were evaluated to determine the most efficient approach, ultimately aligning inventory based on velocity, product characteristics, and operational constraints. The solution also included system and layout updates to ensure the WMS aligned with the new warehouse design.
The optimized slotting strategy is projected to deliver $300K–$600K in annual picking efficiency savings, even after accounting for increased replenishment costs. Net savings are estimated between $150K and $450K per year, driven by reduced travel time and improved productivity. Beyond cost benefits, the new approach enhances scalability, improves pick path consistency, and strengthens compliance with batch and serial requirements. The result is a more efficient, future-ready operation without the need for major facility expansion.
