Leviton US Distribution Facilities-Modern Efficiency for Speedy Delivery
In today’s fast-paced world of distribution, efficient warehouse operations are crucial to meeting customer demands and staying competitive. Over its 115-year history, Leviton has refined its warehouse practices into a highly structured, efficient process and keeps looking for ways to improve. Leviton Insider recently spoke to Ken Wallace, Senior Director of Distribution and Warehousing Operations and he gave valuable insight into Leviton’s warehouse procedures.
Leviton’s High-Volume Distribution Centers
Leviton has two domestic distribution centers. The largest, in Lebanon, Tennessee, ships an impressive 38,000-42,000 cartons per day, and Spanish Springs, Nevada adds even more volume. Together, these facilities ship a combined 60,000 to 65,000 cartons daily. This large-scale volume allows Leviton to fulfill the demands of both small, independent and large, global distributors alike. Each distribution center shares Leviton’s goal for carbon neutrality in energy and water usage, as well as efficient packing and logistics forecasting.
Oracle WMS: Leviton’s Custom Warehouse Solution
Leviton relies on a highly customized Oracle Warehouse Management System (WMS), specifically designed for its AS/400 system, |
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to streamline order fulfillment, control costs, and accurately manage inventory. This system uses RFID scanners to track inventory through barcodes, enhancing both the speed and accuracy of warehouse operations.
Some of the ways the Oracle WMS benefits Leviton’s distribution centers are:
Inventory Tracking: Leviton picking teams can see in real-time, how much stock has been received to the warehouse and how much has been allocated to orders ensuring stock is monitored and available.
Streamlined Processing: From picking to packing and shipping, the WMS reduces time and labor required to fulfill orders, minimizing the risk of human errors.
Productivity and Labor Management: Tracking employee completion rates and productivity, allows managers to hire the optimal number of warehouse pickers and system managers.
The Power of Wave Picking
Warehouses can utilize several methods for picking, and Leviton uses a technique called wave picking. Wave picking is where workers collect grouped items for multiple orders at one time instead of picking each order individually. The groups are based on shipping deadlines, destination, shipping type and priority levels.
Ken explained, “The efficiencies we gain by wave picking are tremendous. When a picker goes to one location for 100 cartons, it is faster and more efficient than going to 100 different places for each carton.” The system is mostly automated, and groups orders by commonalities, making it easier for staff to fulfill. Ken added, “Leviton has a history of investing in process improvements and automation and continues to make these investments.”
Label, Print, and Apply: Preparing Shipments
After each shipment is created, it heads to the Label, Print, Apply, (LPA) area, to have each carton scanned, pallets bundled, and the appropriate labels applied. A unique shipping number is applied, and the shipment begins heading to the staging area for the independent trucks and carriers to be packed.
The Human Element in Leviton’s Warehousing
With all the automation discussed, we wondered, where the human element entered the picture. Ken explained, “At the Lebanon, Tennessee distribution center, |
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there are 115 employees and at the Spanish Springs, Nevada distribution center there are 65. The staff is made up of not only management including supervisors and leads, but warehouse operators, and programmers as well as IT staff.
Timely, Accurate Order Confidence
Leviton is committed to supporting their customers with an industry-leading 24-hour turnaround for outbound orders. With an accuracy rate of 99.95%, nearly all orders from distributors are ready to ship the day after they are allocated by customer service into the WMS. Orders are carefully and quickly picked, processed and packed, then loaded onto appropriate trucks. For distributors and electrical professionals, this quick and reliable processing, is a testament to Leviton’s commitment to customer success.
Helping distributors manage inventory levels and know Leviton is ready to quickly process orders allows them to reduce overhead expenses, and have the assurance that replenished products will be available within 24 hours, allows confidence that the items they need will be at their fingertips. |
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