All Case Studies
Logistics & Distribution
Distribution Center: RFID & Warehouse Automation Transformation
How a distribution center achieved 99.7% inventory accuracy and 30% capacity increase through RFID and WMS optimization.
99.7%
Inventory Accuracy
30%
Capacity Increase
45%
Error Reduction
10 mo
ROI Payback
The Challenge
A large distribution center serving the southeastern US struggled with inventory accuracy at just 87%. Manual scanning was slow and error-prone, leading to mis-ships and excessive safety stock. The facility was running out of capacity with 15% year-over-year order growth.
Our Approach
OPZ360 designed a comprehensive warehouse digital transformation:
1. Current state assessment and process mapping
2. RFID infrastructure deployment (readers, antennas, tags)
3. WMS integration with RFID data
4. Automated receiving and put-away optimization
5. Real-time inventory visibility dashboards
6. AI-powered pick-path optimization
7. ERP integration for automated replenishment
The Results
Within 5 months of going live:
- 99.7% inventory accuracy (up from 87%)
- 30% increase in order fulfillment capacity
- 45% reduction in pick errors
- 25% reduction in labor hours per order
- 20% reduction in safety stock
- Customer satisfaction improved from 3.2 to 4.7/5
- Full ROI in 10 months
Want Results Like These?
Let OPZ360 assess your operations and build a digital transformation roadmap tailored to your goals.