Since 1974, Marmot has produced high-quality technical clothing and equipment for mountaineers, outdoor enthusiasts and extreme Alpinists.
Dramatic business growth and manual distribution processes led to space and operational constraints. Marmot wanted to evaluate potential automation with integration into a new SAP warehouse management system and needed a design to sustain future growth and potential acquisition of new brands.
What Sedlak Did
Evaluated four scenarios with varying levels of mechanization to meet design requirements, including conveyable and non-conveyable product storage and processing.
Selected technologies included: a 3-level pick module, conveyor-fed processing from picking through shipping, a light-directed put wall for small items, and a shipping sortation system.
Led equipment procurement and turnkey implementation of the new 300,000 sq. ft. facility in Reno, NV.
Integrated a new warehouse control system (WCS) to interface with the SAP EWM host system for enhanced functional capabilities and efficiencies.
The project was completed within a tight timeframe.
New operations modal and automation enabled greater efficiencies and positioned the facility for enhanced future automation when growth exceeds the planned horizon projected volumes.
Operations reduced spending as a percent of sales from 3.1% to 2.2% and reduced labor as a percent of sales from 2.2% to 1.6% over the planning horizon.
The WCS interface reduced the need for EWM host system modifications, resulting in lower programming and engineering costs, easier future upgrades, quicker implementation, and less complex security and training.Contingency planning mitigated risk with regard to the SAP integration.