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Northeast Distribution took order accuracy from 90% to 99% — and gave weekends back.
Pen-and-paper picking couldn't keep pace with a growing catalog of hearth products from 58 brands. Here's how ScanForce's Warehouse Management System turned tedious, error-prone picking into a near-perfect process.
Small accessories, big orders, and a lot of paper.
In an industry with a tremendous amount of inventory, many small accessories get picked alongside larger unit orders, making order picking a tedious task for even the most organized facilities. Using manual processes and a pen-and-paper system, Northeast Distribution wasn’t achieving the operational efficiency the team aspired to.
Picking the right quantities and identifying the correct products proved challenging, resulting in a higher incidence of errors. “We had higher than wanted error levels, difficulties with storing our inventory freely without it being manually tracked, and a lot of employees who just wanted to have an easier time doing their jobs,” said Josh Dumond, General Manager of Northeast Distribution.
Manual, Pen-and-Paper Picking
A tedious, paper-based process couldn't keep up with a high volume of small accessories.
Higher Than Wanted Error Rates
Picking the right quantities and correct products proved consistently challenging.
Untracked Inventory Storage
Inventory couldn't be stored freely without it being manually tracked, limiting flexibility.
Significant Labor Hours
Manual processes required a significant amount of labor, straining the team as the business grew.
A smooth install that scaled into a smarter warehouse.
Dumond learned about ScanForce from his Sage partner, Shabnam Munjal. “Installation took only a few days total,” Dumond said. “We did a lot of testing to be safe, but ScanForce was very helpful throughout, and answered all our questions. We were so successful with our installation and setup, that we are now helping our sister company set up ScanForce.”
The team quickly deployed barcode scanning and ScanForce’s Warehouse Management System to increase efficiency and reduce errors. Wave Picking let workers pick multiple orders at a time instead of sorting through piles of paper, while Directed Picking offered a visual guide to the proper bin, creating an efficient picking path. They then added ScanForce’s Multi-Bin module to drill down on inventory tracking to the bin level and maximize warehouse space.
Northeast Distribution also linked vendor part numbers to their own during receiving, and set up default bins with label printing to catch errors before they reached shipping. “We probably had a 90% order accuracy rate. Now, we’re averaging around 99%. Our goal internally is 99.5%, so we’re almost there,” Dumond said.
Wave & Directed Picking
Workers pick multiple orders at once, guided visually to the correct bin along an efficient path.
Multi-Bin Inventory Tracking
Inventory is tracked down to the bin level, maximizing warehouse space and storage flexibility.
Barcode-Driven Receiving
Vendor part numbers link to Northeast's own, catching errors before they reach shipping.
A 50% capacity gain without adding headcount.
We reduced labor; we normally hire an additional person during busy seasons, but this was not needed anymore. We increased our outbound capacity by 50% on a daily average. And our errors have become almost non-existent — this alone would be the ROI
Remarkable gains in throughput. Errors nearly gone.
Northeast Distribution worked several vital features into its processes during the first year on ScanForce, creating a happier and more productive work environment.
ScanForce is our go-to partner for clients who want to make their warehouses more accurate and efficient. They have fast, reliable technology, and their support is top-notch.
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