Outdoor Distributor deploying DynaRack.OS
60% fewer replenishment trips & improved cube utilization
Challenge
A distribution warehouse with 180,000+ SKUs used static rack assignments. Space utilization was poor, racks were renumbered manually when new items were introduced, and operators spent excessive time replenishing because storage locations didn't align with velocity.
Solution
The operation deployed DynaRack.OS, which dynamically activates or deactivates storage locations based on cube and velocity signals. The module allowed racks to reconfigure without manual renumbering and adjusted slot availability in response to SKU mix and movement speed.
Results & Impact
60% reduction in replenishment trips - By aligning high-velocity SKUs with accessible locations and deactivating under-used slots, replenishment frequency dropped significantly, echoing the 60%+ fewer replenishment trips reported for multi-site deployments.
Higher cube utilization - Dynamic activation ensured the warehouse used more of its vertical space, freeing up 15% of floor space for new projects.
Simplified rack management - Operators no longer spent hours renumbering racks; DynaRack.OS maintained location data automatically.
Improved labor allocation - With fewer trips and better layout, pickers could be redeployed to value-added tasks, contributing to an overall productivity increase.