Case Study: BHFO.com achieves 97% same-day shipping and 320 picks per hour with Bastian Solutions' Perfect Pick system

BHFO worked with Bastian to install a perfect pick system to speed up order fulfillment

BHFO.com, an e-commerce retailer in Cedar Rapids, Iowa, needed to move from two-day to same-day shipping, raise picking productivity to 250 items per person‑hour while reducing labor, increase throughput in a smaller footprint, cut picking errors, and manage millions of small SKUs. BHFO.com engaged Bastian Solutions to install a Perfect Pick goods‑to‑person system (four aisles with five robots per aisle) integrated with ZiPline conveyor technology and the Exacta warehouse control system.

Bastian Solutions deployed the Perfect Pick cells (20 robots total), 440 feet of ZiPline conveyor, a PC/PLC HMI and Exacta WCS integrated to BHFO.com’s RetailOps WMS. The solution delivered measurable impact: 97% of orders shipped within 24 hours, a 90% improvement in picking error rate, immediate rates of 320 items picked per person‑hour, daily fulfillment of 5,000 eBay auctions using half the previous labor, and inventory stored in one‑quarter of the prior space.

BHFO.com