Jasco Products Company LLC, an American specialist for consumer electronics and lighting, celebrated the go-live of its Oklahoma City fulfillment center expansion at the end of April 2022. The project was a successful collaboration between Jasco, engineer-procure-construct partner Burns & McDonnell, and warehouse automation integrator TGW.
Over the course of a few months, TGW augmented the existing fulfillment center with a highly automated system that lays the foundation for Jasco's future growth. The extension was implemented during ongoing operations, allowing Jasco to maintain its regular business with their customers.
EASIER HIRING: Automation reduces the number of workers needed, shortens training time, and widens candidate pool
IMPROVED ERGONOMICS: A significant reduction in walking, bending, and lifting limits the physical burden on employees
REDUCED OPERATING COSTS: More is done in less time with optimized processes and efficient automation
FOUNDATION FOR FUTURE GROWTH: The powerful system meets today's needs and provides the flexibility needed for any future scenario
Founded in 1975, privately held Jasco Products Company develops innovative products for international omni-channel distribution that includes home improvement stores, military installations, e-commerce retailers, industrial suppliers, and direct consumers.
Based in Oklahoma City, Jasco offers a full-service experience with sales offices and showrooms located throughout North and South America, plus international offices in Taiwan, Hong Kong, and Shenzhen, China.
Originally, the operation was fully manual, with employees stacking cases into order pallets that were then moved throughout the warehouse using pallet jacks. In the process of fulfilling customer orders, workers traveled over 15 miles a day within the warehouse. This physically demanding work severely limited the candidate pool for new employees.
The new solution does away with most of the walking required to fulfill an order and includes ergonomic workstations where employees no longer have to bend and lift bulky or heavy boxes for both full case or split case orders.
Jasco sells to wholesalers, retailers, and direct consumers, with the new omni-channel solution supporting both full case and split case picking. All full case wholesale and retail orders are sent to one of three TGW SlotStax semi-automated palletizing workstations. There, customer order pallets are built, automatically stretch-wrapped, and labeled for shipping—and done so at waist height, so operators no longer have to repeatedly bend and lift cases.
The split case picking of Jasco products for wholesale, retail, and direct consumers is managed with a TGW FlashPick® goods-to-person system. Four aisles, powered by TGW Stingray shuttles, store and transport goods for order picking to PickCenter One workstations. There, items are ergonomically picked into totes, completely eliminating walking during the picking process and improving order accuracy and speed. Once picked, order totes continue to the packing area, where the items are put into larger conveyable cartons and then sealed and labeled for tracking.
The TGW warehouse software controls and optimizes the picking processes and communicates in real time with the entire system. Unique to Jasco is the software's ability to convert source totes into order totes automatically based on order requirements. The system also can process orders consisting of anywhere from one to eighty or more lines.
Incoming trucks are manually unloaded in the receiving area. From there, the cases are transported into the sorting loop via a network of conveyors. Employees then stack the cases manually onto single SKU pallets that are stored in the high-bay warehouse. The high-bay warehouse is used for replenishing the four-aisle TGW shuttle system, which is connected to two PickCenter One order picking stations. These 1:1 goods-to-person workstations sustainably increase the speed of order picking, improve efficiency and accuracy, and eliminate the time and physical effort spent walking long distances.
After the go-live, Jasco will continue to trust in TGW's expertise and experience: a five-year full-service contract has been signed. TGW's Lifetime Services specialists will ensure that the highly-automated system runs smoothly, reliably, and with a 98% performance guarantee.