Helmet House

Project Background

Helmet House, Inc., one of the largest importer/distributor of motorcycle helmets and accessories, purchased a 200,000 square foot facility near its existing 87,500 square foot facility in Memphis, TN. Helmet House then partnered with Peach State to determine the best facility strategy to meet its future goals.

Project Objectives

• Reduced distribution costs
• Higher DC productivity
• Maximized storage capacity
• Improved shipment accuracy
• Increased DC responsiveness during peak shipping periods
• Increased customer service and compliance

Solution Benefits

• Developed a simple, robust solution that offered expandability, high throughput, low investment and lower labor requirements.
• Picking solution utilized cartons and totes for larger orders offered a flexible solution featuring:
• Zoned picking.
• Conveyor takeaway that reduced travel and enabled a pick and pass picking environment.
• Expandable pick module to accommodate future SKU growth.
• Denser picking module utilizing carton flow and decked racking enabled more SKUs in a smaller area, reducing travel.
• Up to 3x lines/day of picking capacity vs current capacity
• Use of decked rack for reserve storage decreased cost while allowing flexibility should future storage requirements change.
• 46% increase in overall labor efficiency over current facility.