Case Study: Merrill Corporation achieves improved order fulfillment accuracy and 30–35% throughput gains with Honeywell Intelligrated’s Intelligrated Voice

Document Security Drives Need for Improved Order Fulfillment Accuracy

Merrill Corporation, a 3PL that handles complex, confidential and highly regulated healthcare and financial documents, faced rising order complexity (17,000 SKUs across 28 clients) and error-prone, paper-based picking that threatened regulatory compliance and customer satisfaction. Management sought a reliable, automated solution to improve fulfillment accuracy and boost throughput while gaining real-time visibility into operations.

Intelligrated Voice was chosen for its flexibility, low hardware cost and partnership approach, and was deployed quickly with rapid user acceptance. The voice system replaced paper processes, expanded into multiple workflows, and enabled better training and real-time dashboards—delivering a 65% reduction in picking errors (from 99.73% to 99.90% accuracy), a 45% increase in throughput, nearly 50% staffing reductions in equipped areas, and a payback in just over a year.

Merrill Corporation

Murray Muff

Warehouse Manager