Improving Warehousing Efficiency For A 3PL Player - Addverb


The objectives of the automation project for the DC can be broken down into three major parts i.e., implementing a Pick-to-Light system, a Print and Apply system, and a Case sorting module. They wanted to optimise the material flow and streamline the sorting process for break-pack items (items that had to be picked by opening the case), as well as to achieve the throughput requirements. By implementing the Pick-to-Light system, the DC could automate demand handling from both shelving and racking and sort units to crates for stores. Another ask was for a smart conveyor system to transport crates to weight, print and apply stations where handling labels could be applied. Through automation, they wanted to perform store-wise sorting and streamline cases and crates to pallets for ease of loading and delivery. This would help them save major operational and logistics costs to cater to a wider market.

Solution Implemented

The comprehensive approach to optimising the material flow through the warehouse and streamlining the sorting process for break-pack items was involved in the solution. The right SKU mix was identified and a process utilising batch picking and Put-To-Light (Rapido) based sortation was developed in close collaboration with the customer. Multiple put walls enabled with Pick-to-Lights were designed, and dynamically allocated to different categories like Food and Non-Food. To simplify operations, a network of smart conveyors was established to transport crates, reducing picker travel time. The solution also included dynamic mapping of the store for sorting operations, with zoning and sub-zoning created to allow for greater flexibility. Features like ease of integration, multi-coloured lights, and easy installation were provided by Pick-to-Lights, making it a comprehensive solution for optimising warehouse operations. To conclude, our configured warehouse control system ensured accuracy and provided real-time data for the smooth management of all tasks.

Improvement in Key Results (KPIs)

The comprehensive solution developed, which involved utilising batch picking and Pick-to-Light sortation, and establishing a network of smart conveyors, saved significant operational and logistics costs and time while streamlining sorting processes.


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