2020 was a year marked by fear, uncertainty, and stress, but it was also one that led to innovation for many, like Monat Global.  A multinational distributor of premium beauty products, Monat Global had already been planning to modernize its storage and fulfillment processes to meet growing demand, and the pandemic led them to hit the accelerator. For a look into the entire process, check out DC Velocity’s feature, or get the highlights below.

Storage
Back in 2019, Monat Global teamed up with Alpine Supply Chain Solutions to work on their expansion plans. Monat was outgrowing its 70,000-square-foot facility in suburban Miami, FL and with Alpine’s help, they were able to secure a 159,000-square-foot facility in Doral, FL – close to its existing location. This new facility would feature high-density storage, incorporating drive-in-, select, and push-back racking to maximize space and improve overall productivity. Alpine’s storage analysis and facility design/layout streamlined the flow of pallets into and out of the facility. Matt Warner, Monat’s chief operating officer, explained this meant Monat went from 5,000 pallet positions with its previous storage setup to more than 9,000 pallet positions.

Picking
Up until this project, Monat was using largely manual processes when it came to picking which was impeding productivity. By installing conveyors, sorters, a pick-to-light system, mobile computing, bar-code scanning, and SAP’s Extended Warehouse Management (EWM) WMS, they were able to achieve a 48% improvement in lines filled per hour. Overall production through the facility per hour improved by 65%.

Automation
Now that Monat has addressed space constraints and manual processes in FL, they can take those learnings for building a new distribution hub in Dallas, TX. The plan is to build a similar facility with maximized storage space and a variety of automation in place, with an eye on adding new automation technologies as they become available. Monat will also implement a  learning management system for employee training and education, a labor management system, and an automated dock door scheduling system. This is projected to save Monat $3 million.

Alpine’s Managing Principal, Michael Wohlwend says it all comes back to strategic planning, adding that “world-class preparation leads to flawless execution.” For the full story, check out DC Velocity’s feature. If you’re looking for assistance in your warehouse, reach out! We’re here to ensure you get the most out of your supply chain investments.