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Never Satisfied: Ongoing Improvement Projects Cut Cost, Streamline Facility

Challenge: A CPG manufacturer of home appliances needed to control labor expenses and identified a 500,000-sq.-ft. distribution center as an opportunity to streamline. The facility ships to three regional centers and an overflow warehouse.

Solution: GENCO identified numerous continuous improvement projects to enhance productivity and improve efficiency at the facility. The projects included shipping orders directly from the overflow facility, reconfiguring the distribution facility based on frequent ordering, and rounding to full-pallet quantities more often.

Results: Each continuous improvement project resulted in labor savings of up to $350,000. The initial results and a barrage of ongoing projects demonstrated GENCO’s unwavering commitment to improvement-in operations and processes. By applying Lean principles, the customer realized cost reductions, increased efficiency and streamlined processes that continue to keep labor costs low at the facility.

About the Solution Provider: GENCO is the recognized leader in product lifecycle and reverse logistics solutions designed to maximize value and reduce costs. GENCO operates 140 value-added warehouse locations comprising 35 million square feet and manages $1.5 billion in freight annually throughout North America. For more information, visit



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