Case Study: Melaleuca achieves faster, more accurate order fulfillment and supports 8% annual growth with Bastian Solutions' PictureView pick-to-display system

Melaleuca - Customer Case Study

Melaleuca, an international manufacturer of health, home, and personal care products, faced rising labor costs and inefficient order fulfillment because its pick-to-light system required associates to handle every container even when no picks were needed. Bastian Solutions was engaged to modernize their picking operations using PictureView™ “Pick-to-Display” and other material-handling upgrades to address this challenge.

Bastian Solutions implemented a comprehensive system—PictureView pick-to-display, a 2-level pick module, tri-lane pick conveyors with high-speed bi-directional diverts (22 cases per minute), an Ermanco narrow-belt sorter, Mettler Toledo in-motion check weighing, Hytrol pre-sort shoe sorter, Accusort scanners, Exacta warehouse control system, and supporting racks and chutes—that routes containers only to zones that need product and shows on-screen product images for each pick. The solution increased operator efficiency, improved pick accuracy, helped Melaleuca set new records in “each” picking, and enabled the company to support its 8% annual growth rate.

Melaleuca