Andrew S. Collier

Frozen Turkey Warehousing and Retail Distribution Company

Client Challenge

A rapidly growing frozen turkey distribution company was shipping an average of 75,000 frozen turkeys daily, pushing their operational processes to maximum capacity.

✅ The company's exponential growth had outpaced their legacy systems and manual procedures, creating significant bottlenecks in their warehousing operations.

✅ They required a custom Warehouse Management System (WMS) that could automate all workflows related to optimal put-away, picking, and shipping of frozen turkeys by case and pallet, while maintaining lot tracing and tracking capabilities.

Client Solution

I designed and implemented a comprehensive WMS solution:

🔢 1) Process Analysis: Conducted Gemba Walks to understand end-to-end processes and identified bottlenecks.

🔢 2) Collaborative Design: Collaborated with a third-party integrator to blueprint system modules that matched

operational requirements.

🔢 3) Implementation & Training: Oversaw configuration, testing, and user training to ensure successful go-live.

✅ The system reduced shipping errors, improved inventory accuracy, and allowed the client to scale operations with confidence.

Client Impact Results ✅ Eliminated nearly 100% of manual procedures, documentation, and rework according to client feedback. ✅ Enabled the operation to continue growing without adding proportional headcount. ✅ Delivered real-time visibility, lot control, and shipping accuracy exceeding 99.5%.

Client Technologies

✅ Progress Database technology stack (Progress RDBMS, 4GL)

✅ Modern WMS software with barcode scanners

✅ Integration with retail POS and RF scanning devices

✅ Integration with retail POS and RF scanning devices, handheld Zebra RF devices, and label printers