Carlstar Group: LTL & TL Optimization Project

Author

Jacobo CastroFollow
Maia KeithFollow
Stephen PhillipsFollow
Charles SmithFollow

Date of Submission

Fall 12-2-2024

Project Type

Senior Design

Minor

Data Science and Analytics

Major

Industrial and Systems Engineering

Degree Name

Bachelors of Science in Industrial and Systems Engineering

Department

ISYE

Committee Chair/First Advisor

Sohyung Cho

Secondary Advisor

Robert Keyser

Abstract

Kennesaw State University and The Carlstar Group have partnered for the first time to launch the Carlstar TL and LTL Outbound Optimization Project at their distribution center in McDonough, Georgia. Since 2010, this facility has served as a critical hub for distributing Carlstar’s products across the southeastern and eastern United States, as well as to other regions. Following a recent management change and a warehouse overhaul, Carlstar faced challenges in establishing optimal and efficient standard practices to streamline their outbound operations.

Focusing on the three main outbound processes—Picking, Packing/Order Manifestation/Auditing, and Loading—we conducted thorough research to refine and clarify an existing Standard Operating Procedure (SOP). Our goal was to enhance its clarity and usability. Additionally, we developed a Process Flow Map diagram to help the team visualize both the current and improved workflows for their outbound operations. Finally, we conducted time studies for each process to identify delays, inefficiencies, and obstacles that were impacting performance and processing times within the distribution center.