Case Studies > Buyers Products Boosts Productivity and Service with Manhattan Scale™

Buyers Products Boosts Productivity and Service with Manhattan Scale™

Company Size

1,000+

Region

America

Country

United States

Product

Manhattan SCALE
True Fit Systems

Tech Stack

.NET
ERP System

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Customer Satisfaction
Productivity Improvements

Technology Category

Functional Applications - Enterprise Resource Planning Systems (ERP)
Functional Applications - Warehouse Management Systems (WMS)

Applicable Industries

Automotive
Equipment & Machinery

Applicable Functions

Logistics & Transportation
Warehouse & Inventory Management

Use Cases

Inventory Management
Supply Chain Visibility
Warehouse Automation

Services

Software Design & Engineering Services
System Integration

About The Customer

Established in 1946, Buyers Products Company started as a distributor of truck and trailer components and has grown to become a leading manufacturer in the mobile equipment industry. The company boasts vertically integrated manufacturing capabilities, including forging, stamping, laser cutting, CNC machining, robotic welding, powder coating, assembly, and retail-oriented packaging. With over 250,000 square feet of manufacturing facilities, Buyers is committed to listening to its customers and improving profitability and productivity while enhancing the quality of its products and services. The company recently moved into a new 150,000 square foot distribution center to address its tremendous growth, nearly doubling its capacity.

The Challenge

Buyers Products faced significant challenges due to inefficient, labor-intensive processes and tremendous growth in their supply chain operations. The company had been using manual, paper-based systems which required keypunching all data, leading to inefficiencies. With the move to a new 150,000 square foot distribution center, nearly doubling their capacity, Buyers needed to significantly increase efficiency to manage their growing inventory and product flow. Additionally, customers were increasingly requesting more services and documentation, including EDI capability, compliance labeling, and advance ship notices (ASNs).

The Solution

To address the inefficiencies and support their growth, Buyers Products chose Manhattan SCALE for its functionality and .NET-based platform. The solution was implemented in their new distribution center along with a new ERP system. Manhattan Associates provided a team to assist with the implementation process, and Buyers also collaborated with True Fit Systems to develop the ERP interface. The ERP system feeds orders every eight minutes to Warehouse Management, and orders are waved every two hours throughout the day. A conveyor system carries orders to the picking area, where they are directed to one of two packing areas for either parcel carrier or less-than-truckload (LTL) or truckload (TL) shipping. Manhattan SCALE is used for all warehouse functions, including receiving, putaway, replenishment, picking, packing, creating shipping documentation, and cycle counting. In the evening, the system uploads all completed orders to ERP for invoicing.

Operational Impact

Order processing speed increased dramatically, with the ability to process 140-170 LTL/TL orders per day, a 70%-80% increase from four years ago.
Small package orders increased to 1,000 per day, nearly double the previous volume before implementing the solution.
Productivity significantly improved, with the company growing by approximately 50% over the past four years while labor resources only increased by 20-25%.
The system-generated replenishment keeps the flow of product moving efficiently and accurately, enabling better inventory tracking and customer service.
The company continues to improve productivity on an ongoing basis, allowing the addition of new product lines.

Quantitative Benefit

Order processing increased by 70%-80%.
Small package orders increased to 1,000 per day, nearly double the previous volume.
Company growth of approximately 50% over the past four years with only a 20-25% increase in labor resources.