A National Footwear Company Increases Units Picked Per Hour by 70%

At ODW Logistics, we’re committed to helping our clients drive efficiency, reduce costs, and build more sustainable operations. A recent partnership with a national footwear company is a perfect example of how innovative solutions can deliver remarkable results.

The Challenge

Our client, a national footwear brand renowned for durable, high-quality shoes for children and adults, faced several operational challenges. Together, we identified key opportunities to:

• Enhance operational efficiency

• Optimize resource utilization

• Reduce packaging waste

• Accelerate order fulfillment speed

The goal was clear: improve throughput while building a leaner, more eco-friendly operation.

The Solution

Our Continuous Improvement team dove into the client’s operations to analyze their pick-and-pack processes. Here’s how we tackled the challenge:

1. Identify Bottlenecks

We conducted a thorough analysis of the pick-and-pack area and discovered a significant bottleneck in the packing process that was slowing overall throughput.

2. Implement Automation

To address this, we introduced the Auto Poly Bagger solution—a smart system that measures and cuts poly film to fit each box size precisely. This innovation:

• Reduced E-commerce corrugate, shipping boxes, and dunnage by 80%

• Minimized waste and material costs

• Streamlined packaging operations

  
  
  

3. Repurpose Labor

Automation delivered more than material savings. It reduced pack-out labor needs by 30%, allowing us to reallocate staff to the picking area. This strategic move significantly boosted productivity.

The Results

Thanks to these improvements, the national footwear company achieved:

• 70% increase in units picked per hour

• 80% reduction in E-commerce shipping boxes, corrugate, and dunnage

“ODW’s engineering team seamlessly implemented automation and improved the overall efficiency of our operation, leading to a more eco-friendly operation while increasing the overall throughput.”
— National Footwear Company

Interested in discovering how we can help your operations achieve similar results? Contact us today to start the conversation.