CHALLENGE SOLUTION

CLIENT

Spencer Gifts, Inc.

(A unit of Universal Studios)

Pineville, North Carolina

Spencer Gifts, Inc., is a global company specializing in novelty gift items with over 700 stores in the United States, 30 stores in Canada and 7 stores in the UK. Spencer Gifts operates several distinct brands, including Spencer Gifts, DAPY, GLOW!, SPIRIT Halloween Superstores, and Universal Studios Store.

CHALLENGE

Recognizing the need to reduce overhead, Spencer Gifts consolidated two major distribution centers into one. Through extensive automation, they anticipated achieving the combined throughput of the two individual centers, while using only the physical and human assets of the original facility.

SOLUTION

The receiving system for the distribution center was redesigned around an RF put-away system. This system communicated with the warehouse inventory system so that real-time stock locations were achieved.

After processing the orders received, high volume broken case picking was accomplished using a 1,000 SKU zoned paperless pick module. Above the module was placed a “ table top” mezzanine for slow moving items.

High volume items were merged with the slow movers coming from the mezzanine prior to entering the packing area. After consolidation, a bar code shipping label was applied prior to automatic case sealing. As these cartons traveled to shipping sortation, they passed through a full case picking area where full cases were added to the conveyor. Before entering the medium speed shipping sorter, the cases were scanned, weighed by an in-motion scale, then diverted at the proper shipping door.

By utilizing much of the existing equipment, including power conveyor, racks, and carton flow, and by substantially increasing the throughput, Mantissa was able to save Spencer Gifts a great savings both initially and in years to come.

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