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ProMat 2023 Robotics Theater - Zebra: Bespoke Manufacturing Company Accelerating Order Entry to Delivery with Flexible Automation
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ProMat 2023 Robotics Theater - Zebra: Bespoke Manufacturing Company Accelerating Order Entry to Delivery with Flexible Automation

Duration: 0:43:15

Release Date: Apr 03, 2023

With a minimum order quantity of one and a goal to create and ship product within 24 hours, discover how BMC, an on-demand manufacturer of clothing and home goods opted for autonomous mobile robots to move materials among its 120 sewing stations rather than inflexible roller conveyors. Join us for a discussion on how BMC relies on robotics and fixed industrial scanning technologies from Zebra to improve efficiency and triple production capacity.

Key Takeaways


  • Increase the efficiency and visibility of workflows from printing and cutting of the fabric to the final phase of packing and shipping
  • Move, trace and transport workpieces to their destinations along the production line
  • Free workers from non-essential tasks and empower them to focus on high-value responsibilities

Speakers
Cody James
Strategic Account Manager
Zebra Technologies

J. Kirby Best
President and CEO
BMC

Kelly Breneisen
NA RPM Supplies
Zebra Technologies

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Big gains for Big Lots
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Big gains for Big Lots

Situated at the crossroads of the Choctaw Nation in Durant, Oklahoma, Big Lots' 1.2 million square foot distribution center serves 235 stores within a network of more than 1,300 stores across 48 states. Big Lots is a large national discount retailer, providing everything from furniture to food, as well as household goods and seasonal décor.

The Durant facility serves stores in parts of 16 states, stretching from the Canadian to Mexican borders. Such a vast area makes it difficult to find reliable transportation. For years, Big Lots utilized multiple carriers, but the complexity as the chain grew resulted in products not being delivered to stores on time. This complicated retail operations, as products often were not available to sell in a timely manner.

"We have a long average distance to our stores, which made it very difficult to hit the appointment times consistently that our stores expect," explains Kory Shinlever, director of domestic transportation at Big Lots. "We also had issues with DC productivity we needed to solve because we had a lot of transportation partners supporting that store delivery. It made our trailer pool very complex."

Big Lots needed a partner who could replace that complex mix of transportation providers with one dedicated fleet. They found that partner in Ruan.

"The services we provide Big Lots out of the Durant facility are dedicated contract transportation, yard services, as well as brokerage services during times of surge or other nuances that they have within their network to support," says Jeremy Carmichael, vice president of operations at Ruan. "Our partnership with Big Lots is one of a similar culture. Being people-first and people-oriented, we believe in enduring partnerships. We believe that shared culture fosters a long-term relationship."

Big Lots has improved service dramatically since moving its store deliveries to Ruan. Trailers are always available at the Durant DC, something that was a problem before and slowed down distribution operations.

"It's a great partnership from senior management down to the local management here," says Edwin Boothe, Big Lots' director of distribution at the Durant DC. "Drivers are courteous, professional, and they do a good job with the store personnel. On-time percentage has been great. Service levels have improved since we've been with Ruan."

"The working relationship is amazing," adds Holly Valcik, Ruan's dedicated transportation manager who works onsite in Durant. "The team here at Big Lots has been amazing and very supportive. Anytime I have any questions or needs, they are there to support me."

"Our stores from the Durant distribution center now are serviced at the highest level they ever have been at this point," notes Shinlever. "That makes a huge difference to the stores because they're able to improve their productivity. The stores don't have associates waiting for the truck. And because of that, they're more efficient at the unload. They've improved not only their productivity, but they decreased their total detention costs."

He adds that productivity at the Durant DC has also improved since Ruan right sized the trailer pool with units now always available at the 40 outbound doors. Warehouse associates can finish their picking and not have products stacking up at the docks, as trailers can be loaded on time.

Shinlever says that with Ruan, they found a long-term partner. "We wanted a partner who would be able to solve solutions at scale, who could grow with us and also matched our own company culture - one of being able to succeed together and playing to win," he shares.

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