Malouf’s engineering team created custom software to increase the efficiency of the company’s conveyor system to speed up fulfillment during the pandemic.
LOGAN, Utah — Bedding and furniture brand Malouf has implemented several strategies to accelerate order fulfillment during the pandemic, including upgrading the software for its conveyor system.
“Over the years, we have tested and installed dozens of software solutions in our warehouses to increase our shipping speed and efficiency,” said Erfan Reed, Malouf engineering team manager. “When we acquired the Dallas warehouse, we identified an opportunity to integrate our in-house technology to provide better service to our retail partners.”
When Malouf initially purchased its distribution center in Dallas, the center had six miles of conveyor belts consisting of 10 separate lines and three pick modules that lacked efficiency. To streamline the order fulfillment process, Malouf’s engineering team created automated software for the conveyor system by using the company’s own warehouse and inventory management software.
Reed and members of his team built new custom-printed circuit boards and wrote software compatible with the building’s 20-year-old scanners, promoting quicker fulfillment and delivery times. Since applying these updates three months ago, the company has eliminated several hours of manual labor per week and decreased its processing time by nearly 50% per item.
The company is now implementing the same software in its newly acquired warehouse property in Delano, Calif. Previously a distribution center for Sears, the 1.2 million-square-foot building features 12 miles of conveyor belts with more 20 pick modules. Reed said he expects the new conveyor system to be ready later this year.