A distillery client was experiencing dock coordination issues at their Distribution Center (DC). There was no appointment scheduling for pickups; it was first come first served methodology when it came to loading carriers each day. The DC personnel had little idea whom would show up each day to pick up the finished good loads / orders. Issues included carriers showing up too early (as in days or hours) or too late (as in days or time of day) or not at all.

Top Shelf Logistics arrived on site and studied the issues for a short period of time and with client’s logistics team collaboratively developed a supply chain solution to alleviate the inefficiencies. Our multiple goals were to eliminate the congestion in the yard, create short and mid-term visibility with dependable schedules, utilizing every loading slot to maximize employee and order throughput while minimizing carrier detention and stockouts.

First, we migrated the operation to an appointment only pickup process for all shipments, which mirrored the workforce schedule. We then reverse engineered forecasted cases to determine daily loading slots needed for carrier pickups. By actively working within a warehouse management system (WMS), we utilized required ship dates and carrier names in a routing guide format and began scheduling orders. Results include staffing efficiencies. Overtime and detention charges reduced. Through extending the order planning horizon and visibility, working stock out issues, load leveling was quickly achieved. Facility became a “carrier friendly” dock, maximized throughput, increased loading capacity and flexibility.