Case Study: Hendrickson achieves major warehouse efficiency gains and reduced picking errors with QAD Automation Solutions

Hendrickson - Customer Case Study

Hendrickson, a global manufacturer of truck and trailer suspensions and related components with 25 plants and over $1.3B in revenue, struggled with inventory visibility and inefficient material flow because each plant combined manufacturing and distribution. Paper-based pick lists, multiple moves of the same items, long lead times and incompatible off-the-shelf WMS solutions left work centers and shipping areas waiting for materials and required extra handlers and equipment.

Working with QAD, Hendrickson implemented two custom automation modules—Purchase Order Directed Put Away and Sales Order Bulk Pick—based on zone-based inventory locations, real-time pick calculations and consolidated picklists. After a pilot and companywide training, the solutions delivered major gains: 40% improvement in material handler efficiency for put-away, 30% improvement in packer efficiency and 60% in material handler efficiency for bulk picks, plus a 30% reduction in picking errors and a 50% reduction in picking lead time; the modules are now being rolled out across other plants.

Hendrickson

Scott Aselage

Plant Manager