OVERVIEW
An Amazon fulfillment center in Delaware, serving third-party sellers, faced operational inefficiencies due to manual workflows, paper-based documentation, and reliance on staff memory. EpicRise stepped in to modernize the facility by introducing barcode scanners, mobile computers, industrial printers, and a cloud-based Warehouse Management System (WMS). Within a short 6 months, the transformation resulted in faster operations, improved accuracy, reduced costs, and a more streamlined workflow.
BACKGROUND
The fulfillment center handled approximately 10 inbound and 10 outbound pallets daily with a team of eight employees. Despite their dedication, the absence of a WMS and reliance on Excel spreadsheets created bottlenecks and scalability issues. Aisles were frequently congested, packaging supplies were inconsistent, and safety protocols were loosely enforced. These challenges limited the center’s ability to grow and maintain accuracy.
KEY CHALLENGES
- Manual workflows lacked barcode tracking and system integration, slowing down
receiving, put-away, and outbound processes. - Congested aisles and staging areas disrupted the flow of goods and reduced operational efficiency.
- Packaging supplies were inconsistent and costly due to ad-hoc sourcing.
- Limited zoning and paper-only documentation created compliance and safety risks.
- Existing processes weren’t scalable, posing risks to accuracy and future growth.
EPICRISE’S APPROACH
EpicRise conducted a comprehensive audit and proposed a three-pronged strategy focusing on systems, space, and technology. A cloud-based WMS was implemented to digitize receiving, put-away, picking, and shipping. Waybills and packing lists were archived digitally, and cycle counts with discrepancy logs were introduced to enhance accuracy and audit readiness.
Space optimization included vertical pallet racking, phased zoning, and the introduction of location identifiers with durable barcodes. Functional zones such as receiving, staging, and returns were clearly defined, and safety was improved by enforcing a 'nostorage-in-aisles' policy.
Technology upgrades featured Zebra thermal printers and rugged handheld devices for real-time scanning and inventory updates. Barcode scanning was expanded across all functions to reduce errors and improve traceability.
SOLUTIONS DELIVERED
- Mobile Computers: Honeywell CK65
- Printers: Zebra ZT411
- Scanners: Zebra DS2278
- WMS Implementation:
- Real-time inventory visibility
- Structured put-away and internal circulation tracking
- FIFO/FEFO enforcement
- Full traceability with digital logs
- Created standardized SOPs and provided onsite worker training
SOLUTIONS DELIVERED
EpicRise deployed a lightweight, scalable WMS tailored for the mid-sized team. Although the customer handled the physical setup of shelves and aisles, the new layout significantly improved efficiency. Hardware upgrades included Zebra printers (ZT411) and rugged handheld terminals (Zebra DS2278). Process improvements such as cycle counting, discrepancy reporting, and digital archiving were introduced. Mobile computers (Honeywell CK65) were recommended to save time during put-away, picking, and counting. Packaging supply channels were consolidated to ensure consistent quality and reduce costs.
RESULTS
Within six months of implementation, the fulfillment center saw measurable gains in accuracy, cost control, and process efficiency:
- Labor efficiency improved by ~20%, saving the equivalent of $65,000 annually on payroll.
- Inventory accuracy increased from ~75% to 95%, minimizing stock discrepancies.
- Put-away time reduced by 40%, aligning with industry best practices.
- Aisle congestion decreased by 30% through improved zoning and racking.
- Packaging costs lowered by 15% due to standardized sourcing.
- Training time reduced by 35%, enabling quicker onboarding.
- Error-related customer issues decreased by 50%, strengthening service reliability.
Customer Testimonial
“Before EpicRise, we were stuck using spreadsheets and paper to run the warehouse. It got the job done, but it was slow, stressful, and mistakes added up. After EpicRise brought in scanners, mobile printers, and a better layout, everything changed—we’re faster, more accurate, and saving real money. Now the warehouse finally works for us, not against us.”
CONCLUSION
EpicRise’s structured audit and roadmap enabled the fulfillment center to transition from manual recordkeeping and ad-hoc practices to a digitized, standardized, and scalable operation. The project delivered measurable improvements in operational efficiency, compliance, safety, and cost control. This case demonstrates how EpicRise empowers fulfillment centers to achieve higher accuracy, stronger compliance, and sustainable growth.
