E-commerce DC using Slot.OS
30% reduction in picker travel & 20% throughput lift
Challenge
An e-commerce DC struggled with long picker travel distances and static slotting during peak, driving picking cycle times to miss SLAs. Inventory placement was based on outdated rules and manual analysis. As order volumes grew, labor costs increased and fulfillment times slipped.
Solution
FORGE implemented Slot.OS, an optimization module that scores slotting opportunities and supports velocity-aware placement decisions. Slot.OS tied slot changes to downstream pick-path performance and continuously re-evaluated inventory placement using live demand data.
Results & Impact
30% reduction in picker travel - Slot.OS shortened pick paths by clustering high-velocity items and relocating slow movers, aligning inventory with demand.
20% increase in throughput - Orders were processed faster because pickers spent less time walking and more time picking, contributing to a throughput increase within the first quarter.
Rapid ROI - The project paid for itself in under six months thanks to lower labor hours and improved cycle times.
Scalable slotting intelligence - The DC can now adjust slotting in real time as new SKUs or promotions arrive, without manual re-analysis.