ZR Z R Data Systems, Inc.

office (513) 698-8800
fax (513) 698-8805
toll-free (877) 967-3282
info@zrdata.com


Standard Process

Client Description

Standard Process, of Palmyra, WI, has been a leader in the field of nutritional supplements for over 70 years. The company is committed to a whole food philosophy first introduced by its founder, Dr. Royal Lee. Dr. Lee believed that the best sources of vitamins and minerals are found in whole foods. To preserve the nutrients of the whole food, concentrated supplements are created using a unique manufacturing process. This process involves raw foods grown on company owned farms; state-of-the art manufacturing equipment, and continual testing to ensure quality control. Standard Process Inc. ships to 20,000 healthcare professionals including doctors, nutritionists, chiropractors, and nurse practitioners all over the country.

Need

Before contacting ZR Data Systems, Inc. Standard Process performed all warehouse operations manually on paper. Standard Process was using an outdated management system that had update lag times as long as 30 days. Standard Process had no warehouse visibility resulting in personnel having to physically search the warehouse for goods. There were no formal procedures for put away, inventory or shipping.

Standard Process realized they had to replace its system with an up to date, best-of-breed warehouse management system. However Standard Process required a system that could still work with their current accounting system and whatever ERP system replaced it. The new WMS system would also have to by Windows 2000 compliant, SQL Server based, and RF capable.

The System

Receiving

Standard Process will handle all receiving through the Receipt from Production and Receipt from Vendor processes. These processes will handle incoming product and produce pallet labels to identify product for storage.

Transfers

The transfer of materials into the warehouse from other storage facilities and transfer of materials from the warehouse to outside storage facilities will be handled through the Warehouse Transfer In, Warehouse Transfer Out, Inventory Decrement, and Inventory Increment processes.

Picking

Order fulfillment will be handled through the single order picking. Product can be picked to either a staging location or directly to the dock door.

Standard Process will incorporate Lighting Pick pick-to-light system into its picking process. Operators will place cartons on conveyor system that passes Lighting Pick picking stations. Pickers with RF handhelds will scan the container label and Lighting Pick will indicate what must be picked for that box. After picking is complete the container will be taken to the packing station via the conveyor and then staged or taken to a door location.

Loading

Loading will be accomplished through System-directed and Non-directed loading. System-directed Loading will require the user to enter and order number, a door location and then  verify each line of the order including item, lot, quantity and line number. Non-directed loading will simply require an order number and a door location.

Auditing a Load

Shipping

Standard Process will utilize Kewill's K-Ship manifesting system. The WMS system will be responsible for writing order data to K-Ship and reading back tracking numbers, freight cost, expected pickup, expected delivery, etc.


Outcome

Standard Process was able to eliminate physical inventory and its associated labor costs all together, relying on quarterly cycle counting. The company has also been able to maintain its high level of customer service as it has grown. 

Client Feedback

"We've increase packages shipped per labor hour and shipping efficiency by 50 percent." -Scott Anderson, Standard Process Plant Manager

 "Even with steady growth, we've managed with existing warehouse space which would have been very difficult, if not impossible, without the new system." -Scott Anderson, Standard Process Plant Manager

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Quick Facts

Industry: Pharmaceutacles

Headquartered: Palmyra, WI

Key Processes: Integration with Pick-to-light system, integration with Kewill K-Ship shipping system, System-directed loading

Warehouse Size:

Warehouse Floor Personnel: