Frozen Turkey Warehousing & Retail Distribution — 75,000 Turkeys Shipped Daily
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
Designed and developed a custom Warehouse Management System in Progress RDBMS/4GL — the client’s required technology stack.
Process Analysis: Gemba Walks to understand end-to-end put-away, picking, and shipping and identify the bottlenecks
Application: User roles with authorization, FIFO put-away sequencing, inventory transactions, picking optimization, and real-time barcode integration for forklift operators
Product Data: On-hand inventory by location, bin, license plate, case, and lot; product costs; full lot tracing and tracking
Implementation: Collaborated with a third-party barcode/scanner implementation firm; conducted client education and training through go-live
Client Impact Results
Close to 100% of manual procedures, documentation, and rework eliminated, per client feedback
Fully automated WMS with real-time barcode integration delivered on timeline and budget
Real-time inventory visibility and lot tracing by location, bin, license plate, case, and lot
Client Technologies
Progress RDBMS and Progress 4GL (client technology requirement)
Custom WMS — FIFO put-away, picking optimization, lot tracing
Barcode/scanner integration for forklift operators (third-party implementation firm)
