Approach

During our free 10-hour Business Review and 2-day on-site analysis, we identified the need for tighter inbound/outbound rhythm, smarter slotting, and a defined supervisor layer—plus updated Standard Operating Procedures (SOPs), clear Responsibility-Assignment (RACI), and a daily Key Performance Indicators (KPI) dashboard—all mapped to their QuickBooks + Extensiv stack (workflows, roles, and reports aligned to what they already use).

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Focus — Project Implementation (what we actually installed and how it ran)

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• Inbound cadence: Door schedule, staged receiving zones, and a visible dock-to-stock timer tied to Extensiv receiving.

• Smart slotting: ABC velocity re-slotting; fast movers near pack; system-directed putaway tasks through RF.

• Pick/pack standard work: One best way for batch vs. discrete pick; scan-verify; cartonization rules.

• Cross-dock lane: Marked staging with cut-offs; direct put-to-outbound to bypass storage.

• Supervisor layer: Leads per zone (receiving/pick/pack/ship) with role permissions and an escalation RACI. (RACI = Responsible, Accountable, Consulted, Informed)

• Daily dashboard + huddles: 10-minute shift start using Extensiv/QuickBooks KPIs: lines picked/hr, order accuracy, OTD, dock-to-stock, labor hours/order, incidents.

• Overtime guardrails: Labor plan vs. forecast; flex pool; approval gates before OT.

• SOPs & training: Short SOPs (receiving, pick, pack, ship, cycle count); buddy training and weekly audits.

• Cycle counts: ABC program with variance thresholds and CAPA log. (CAPA = Corrective and Preventive Action)

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90-Day Results

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• Dock-to-Stock time −46%; receiving accuracy 98.4% → 99.7%.

• Order accuracy 98.6% → 99.7%; OTD 89% → 97%.

• Labor hours per order −15%; overtime −28%

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6-Month Results (Business Impact)

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• 6-Month Results:

• Customer churn −50% (service-level stability).

• EBITDA margin +2.1 points; warehouse incident rate −33%; stronger supervisor bench. (EBITDA = Earnings Before Interest, Taxes, Depreciation, and Amortization)