Martin’s Famous Pastry Shoppe, Inc.® a distinguished bread and roll manufacturer, faced the challenge of scaling their warehouse operations to meet the increasing demand across 16 countries. With a storied legacy of delivering exceptional quality and taste, Martin’s needs to innovate their fulfillment processes to maintain their competitive edge. Seeking to address these needs, the company turned to automation to enhance efficiency and streamline operations.
As Martin’s expanded its product line and customer base, managing a growing inventory of diverse SKUs and fulfilling intricate orders manually became increasingly complex. The company encountered significant challenges including inefficiency space utilization, labor-intensive processes, and the need for greater order accuracy. These issues impeded growth and operational effectiveness, necessitating a comprehensive solution to optimize their warehouse management.
To overcome these challenges, Martin’s partnered with Westfalia Technologies and implemented a cutting-edge automated storage and retrieval system (AS/RS) integrated with advanced material handling solutions and a Savanna.NET® Warehouse Execution System (WES). The AS/RS featured high-density storage and retrieval machines, which optimized pallet handling and storage. Meanwhile, the WES coordinated operations seamlessly, ensuring precise inventory management and efficient order fulfillment.
AS/RS Footprint: 15,250 sq. ft.
AS/RS Pallet Storage: 1,868 positions (19,000 trays)
Storage: 6-deep storage lanes
Outbound Order Staging: 5 lanes x 9-deep
2 tandem-pallet Satellite® S/RMs in 1 aisle, 4 levels high
Automated replenishment to Cimcorp Robotic Tray Picking System
Automated outbound order staging system
Savanna.NET® Warehouse Execution System (WES)
The implementation of Westfalia’s automated warehouse solutions delivered remarkable results for Martin’s. The system increased space utilization by 50%, improved labor efficiency by 50%, and achieved an impressive 95% order accuracy. The automated layer picking system accelerated throughput times for outbound orders, eliminating the need for reloads and ensuring timely and accurate order fulfillment. These enhancements not only optimized operational efficiency but also elevated customer satisfaction, reinforcing Martin’s position as a leading manufacturer in the bread and roll industry.
