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Date of Submission

Spring 4-22-2020

Project Type

Senior Design


Industrial Engineering


Industrial and Systems Engineering

Primary Advisor

Adeel Khalid


The purpose of this project was to create and implement a new process to transition from a floor loading to a palletized system for product shipping. This change was given at the request of the client. The previous pick row and floor loading system was insufficient to the client due to added expenses in the form of safety, excessive lead times, labor hours, and damages. While averaging approximately 135,000 cases a week, with a cost per case of $0.320, this distribution center was spending $2,264,837.12 annually in total labor cost with $269,907.93 being contributed to an insufficient pick row layout. With this transition comes the opportunity for improvement and the potential of associated risk. The goal of the proposed redesign is to reduce the labor cost per case from $0.320 to a minimum of $0.295 (8% reduction/improvement), reduce safety near misses by 5%, and reduce customer complaints/item damages by 5%.