Case Study: Implementing a Pack to Light Solution
in a Major Retail Distribution Center
by Greg Morneau

Sekel Associates Brought Focus and Leadership

When Greg Morneau of Sekel Associates undertook the project management of our client’s  PTL installation, he quickly determined that, due to the ongoing upgrades in the DC, organization and a focused approach to a phased implementation would be key to success. He began with a detailed approach to requirements gathering. In essence, due to the nature of this particular project, there were two sets of requirements. The first was a thorough analysis of the existing DC operation which would lead to list of requirements for process improvement. Key factors which needed improving were the DC throughput for order fulfillment and the error rate resulting from the manual carton packing and lack of manifest documentation accompanying the shipped cartons.

The second set of requirements dealt with the logistical approach to implementation needed to ensure that a preliminary installation could be put in place with existing conveyors belts and shelving and then a final installation would follow the warehouse upgrade of shelving and conveyor belts. The approach was critical because the price advantage would not be available to our client if they waited until after their planned upgrades were in place.

Sekel Associates leveraged their experience in project management, system implementation and the retail distribution process to come up with the right solution. Morneau made a point of defining the appropriate scope for the project at both phases and then ensuring the team stayed within scope and were able to complete the project within the projected schedule.

Executive leadership within the client company was motivated and responsive. When consultants are called in to lead an effort as complex as this one, support from Executive Leadership is absolutely critical to success. In large part the success of this project was because the Vice President  stayed in touch with the project team and kept himself apprised of status, giving his support where needed. Another factor that contributed to the success of this project was the fact that the PTL system vendor had a strong installed base and was skilled in implementing their system under various different circumstances.  It also worked to our advantage that the Host developer was dedicated and knowledgeable with a strong business sense as well as outstanding technical competency.

Essential factors, therefore, to a successful PTL implementation are a well-rounded team with experience and technical expertise in the solution domain, a clear focus and comprehensive requirements analysis, along with the right technical solution and a technical engineering team who understand how to interface new technologies with existing legacy systems supporting your enterprise.