Food Retailer Saves $500K–$700K Annually by Eliminating Store Staging Lines

Client Profile
A nationwide food retailer needed to optimize its distribution network to handle increased volumes, more SKUs, and growing demand for customized/e-commerce orders with rapid store deliveries.

Challenge
Traditional store staging lines consumed significant floor space and required extra handling. The retailer wanted to eliminate these lines while improving picking and loading efficiency to support faster, more flexible order fulfillment.

Approach
CapRock applied a structured 9-point program focused on converting the distribution network to a streamlined picking and loading environment. Key elements included: - Time studies and process analysis of picking and loading operations - System and layout optimization - Direct loading into outbound trailers without intermediate staging - Collaboration with client engineering and operations teams

Results – Identified how to completely eliminated store staging lines and transfer positions – that would reduce  order turnaround times and improved responsiveness to customer needs – and loading FTEs by 25% - This would Free up valuable warehouse floor space - Delivered estimated network-wide direct labor savings of $500,000–$700,000 annually (based on reduction of 15–20 FTEs) - Achieved ROI in less than 3 months

Key Outcome
By redesigning the picking and loading process using time study data, the retailer dramatically improved speed, reduced labor costs, and reclaimed warehouse space.