News

A niche product distributor faced an increasing product return rate. They needed to decrease processing time per unit, while optimizing labor utilization. Tasked with accelerating returns and multiple store replenishments – their old system could not keep up. This resulted in an increased time for shippable and saleable returns. Systems in Motion delivered an automation solution with both increased throughput, and labor efficiency. Challenge: They needed to significantly improve the returns throughput, Also optimize their returns operations, With limited space to expand. Required more product destinations, and a process which allowed for continuous induction. Goal: Sort returned items and transfer them to pickable locations within the same day as received. Current Process:  The original solution was a manually fed conveyor system which had 82 destinations for sorting.  Operators would manually sort to 1 of the 82 destinations. When a single item was allocated to a destination, no other SKUs could be assigned to this location.  With a limit of 82 destinations and over 500 SKUs in a return lot, they had multiple waves. Some of the waves had the same SKU’s with only 1 or 2 items. The number of destinations was the limiting factor in optimizing the returns process. Original manual fed Conveyor System Recommendation: We recommended the OPEX Sure Sort® automated sortation system to: Expand storage destinations to 268 unique locations. One manual induction zone. Make use of Vertical Space due to limited floor space. WCS interface to assign SKUs to appropriate sort locations via their WMS. The OPEX Sure Sort® system operated with Systems in Motion’s KOZ Automation software New Process: KOZ Automation software received bulk inventory lists from the customer’s WMS (Warehouse Management System) WMS/KOZ pre-assigned quantities and product sizes to the appropriately sized bin. This optimized the number of destinations. KOZ was also able to let operators know when the destination was full.  Sweep operators would remove the totes and replace with empty totes to allow additional SKUs to be assigned to these destinations – all while the induction operation continued. Full totes were assigned to the correct location in the warehouse and then conveyed to locations for automated replenishment. Product was available to pick within a few hours of receiving.  Results: Maximize Destinations – The final OPEX Sure Sort® design quadrupled the operable size to 268 destinations. High Throughput – the system now processes up to 2400 units per hour (UPH). Improved Utilization – from dock to pickable unit in less than 8 hours. Systems in Motion is committed to provide innovative solutions which meet your needs. The OPEX Sure Sort® system is just one example of how we help businesses optimize their operations and achieve their goals. If you’re looking to enhance your operational processes, contact us today to learn more. Contact us at www.systemsinmotion.com for your custom solution. Or call 800-687-9091.

Last week, two of our team members, Kevin and Jeff, had the opportunity to attend the MHI Spring Meeting — an annual event that brings together professionals from across the material handling industry to network, learn, and collaborate on the future of supply chain innovation. Held in a dynamic and engaging setting, the Spring Meeting offered a wide range of sessions and workshops focused on the latest trends, challenges, and advancements in material handling and automation. For Kevin and Jeff, it was more than just a learning experience — it was a chance to connect with industry peers, gain fresh insights, and better understand how MHI is supporting companies like ours as we continue to grow and innovate. MHI plays a vital role in driving the industry forward, and it was inspiring to see firsthand the organization’s commitment to supporting members through education, advocacy, and collaboration. Topics at the event included workforce development, technology integration, and emerging best practices — all of which align with our own goals at Systems in Motion. Kevin and Jeff returned energized and full of ideas, ready to share what they learned with our broader team. Events like these reaffirm the importance of staying connected, staying informed, and staying curious. We’re proud to be part of the MHI community and grateful for the chance to participate in such a well-organized and meaningful event. Here’s to continued learning, collaboration, and progress in the material handling industry! Give us a call today.1-800-678-9091. Add Your Heading Text Here

At Systems in Motion, we take pride in supporting the communities where we work, live, and play. That’s why we’re excited to announce our sponsorship of the 2025 MAVPAK Pallet Games — an event that’s more than just competition. It’s about connection, community, and giving back. The Pallet Games bring together individuals and businesses from across the packaging industry for a day filled with teamwork, energy, and purpose. It’s a unique opportunity to celebrate the people who power our industry while raising support for local causes that make a real difference. We believe in showing up for the people behind the products, processes, and partnerships that drive our work every day. Sponsoring the MAVPAK Pallet Games is just one of the ways we live out that commitment. We’re proud to be part of something bigger — and we hope to see you there.. Give us a call today. 1-800-678-9091.