Bolingbrook, IL The next time you wash your hands, if you look at the sink, chances are you'll see the name Elkay on it. Elkay manufacturing is a worldwide distributor of plumbing fixtures, such as sinks and faucets. In November of 2000, Elkay moved into their new 100,000 sq. ft. distribution center in Bolingbrook, IL. Elkay wanted to utilize the new facility's 55,000 additional square feet of space as efficiently as possible. Thomas Conveyor and Equipment, a systems integrator located in Hillside, IL (708-449-2100), assisted Mallard Manufacturing Corporation in designing a system that would keep individual SKUs safely stored and organized for easy selection. Due to the self-guiding nature of the pallets, Mallard #328 skate wheel, mounted on RF125 channel was chosen to distribute the 700 SKUs Elkay stores in flow racks. Number 35 speed controllers are used to keep pallets moving at a controlled rate of flow.

Every day approximately 100-120 pallets of product arrive at the D.C. from plants in Illinois and North Carolina. Mallard live storage systems help to keep the units separate and in the proper position. In Elkay's case this is particularly important because the pallets are loaded full, and units are picked off individually from the pallets. At the old facility, pickers entered the static racks and physically searched for misplaced units. By keeping product organized and accessible, less demands are placed upon employees, unnecessary movements are eliminated, and safety is increased.

Thirty-eight people were required to accomplish the task of distributing in the old facility. With the addition of gravity flow storage, thirteen employment positions were eliminated. Two-thirds of the employees previously required are operating a distribution center over twice the original size! Elkay operates two 8-hour shifts, with plans to drop to one 14 hour shift. This is a labor savings from the three, 8-hour shifts at the old facility. In the volatile business market, where speed and accuracy are necessities, order fulfillment is a major concern. Not only did the number of employees decrease, but order fulfillment went from 1.6 days to .4 day; a 400% faster fulfillment!

In these days of litigation and high insurance costs, we will know the importance of employee safety. Elkay reported three work related injuries last year, according to Mike Brisco, warehouse supervisor. This year there have been NO accidents reported. Not only is the safety of employees a factor, but also the safety of the products being shipped. Brisco estimated that in the old DC, 40-50 units per week were damaged, most of which occurred as entire pallets toppled from the static rack. Thanks to design and speed assurances developed through extensive laboratory testing at Mallard, no loads have been damaged at the new facility.

So whether you are looking for more efficient use of your space, first-in, first-out operation, a streamlined workforce, or simply a safer working environment, the addition of Mallard gravity flow systems is an integral part of the solution. For more information and the name of a Mallard distributor near you, please contact us.