Multi-Site Distribution Network implementing FORGE Warehouse.OS
30% throughput increase & 20% labor cost reduction
Challenge
A retailer operated five distribution centers, each with its own legacy WMS and ad-hoc labor management practices. Planning and execution were disconnected, slotting and pick paths were static, and deploying new processes took years. Labor costs were climbing even as customer service levels suffered.
Solution
The network adopted the full Warehouse.OS platform, incorporating modules such as Path.OS for ML-driven pick-path optimization, Slot.OS for inventory placement, DynaRack.OS for dynamic storage, Allocate.OS for smarter picking methods, and Twin.OS/Brain.OS for simulation and reinforcement-learning-driven optimization. The system integrated with Phoenix PGS for staffing decisions, creating a unified decision layer over existing WMS infrastructure and performance optimization.
Results & Impact
30% increase in throughput - Network-wide throughput rose due to optimized travel (20-40% pick-path reduction), dynamic slotting and continuous re-optimization; this aligns with the platform's reported 20-40% throughput gains.
40% reduction in labor costs - Leader tools for performance improvements, better slotting, pathing and allocation reduced wasted motion and labor hours, beating the platform's estimated 15-30% labor cost reduction range with combined with Phoenix PGS.
Deployment 3x faster than a typical WMS overhaul - The network went live in under a year, a 70-90% reduction in deployment time.
Rapid ROI - The investment paid back within nine months, consistent with the platform's 6-12 month ROI estimate.