Outset Media Maximizes Space and Meets Increased Demand with Modula VLMs

Case Study Summary

Outset Media, a distribution center located in Brampton, Ontario, is a supplier, manufacturer, and distributor of jigsaw puzzles and board games throughout Canada and America. With a rapid increase in demand for their product over the past few years, Outset Media was at a critical juncture. Their facility was over capacity, and they had to face the decision to downsize, purchase additional warehouse space, or find an alternative solution to pallet rack storage.

With the installation of the 4 Modula ML50Ds, Outset Media was able to save 4,000 square feet of floor space by storing their direct-to-consumer inventory inside the VLMs. Thanks to the intuitive software design and ease of use, one picker can now fulfill orders three times the rate it previously took them. The warehouse can now keep up with order demand for their growing business without purchasing additional real estate in the Brampton location.

The Challenge

With real estate at an all-time high, direct-to-consumer orders spiking, and a current warehouse that was over capacity, Outset Media was struggling to find a solution that would allow them to keep order pace without the high cost of increasing their footprint. Their traditional rack and pallet shelving system had reached the end of its storage capacity, and the picking times could not keep up with shipment demands. Instead of downsizing, Outset Media decided to research automated solutions that would answer their efficiency and storage needs, both immediately and in the future.

The Solution

After consulting with a trusted partner and seeing Modula VLMs at work in another company, Outset Media decided to purchase four 23’ high Modula units. Storing their Cobble Hill puzzle line for their direct-to-consumer business, as well as their small, low-volume items for their wholesale business, Outset Media saved over 4,000 square feet in their warehouse.

Using the vertical space in their facility, the distribution center was no longer over capacity, nor did they have to face downsizing. In addition to saving storage space, Outset Media line workers could pick at rates up to three times their previous picking time with inventory stored on racks and shelving.

The Warehouse Management Software (WMS), easily integrated into their inventory system to keep track of direct-to-consumer orders. It also shows graphical visualization of the tray layout with product location and quantity. The LED bar quickly shows the picker which product to choose for the shipment. Dual internal delivery bays increase the speed and efficiency of continuous picking.

Gurmeet Dhillon, Assistant Manager at Outset Media, remarked on the quick training process to operate the VLMs: “For me, it just took one day to learn everything – how I can put away, how I can pick from the Modula. Everything is clear on the co-pilot, so it is intuitive and easy to navigate.”

In addition, she explained that it used to take a specially trained forklift operator to navigate and pick from the rack and shelving inventory. With Modula VLMs, anyone can be trained to operate within just a few minutes.

With the floor space saved, Outset Media is ready to face a future of continued growth – citing that their direct-to-consumer business grew to now being in their top 20 customers. Shaun Krysa, Director of Operations, was enthusiastic about the outcome of their automated storage VLMs. “I would highly recommend Modula to another company. The Modula units have saved us a lot of time, and a lot of space in the warehouse that we had unavailable to us in the past,” he said.

Instead of looking to downsize, the Modula units have increased their storage capacity, allowed them to keep up with increased orders and enabled them to continue growing their business “full steam ahead.”

Key Benefits of Modula VLM

• Saves over 4,000 square feet of storage space
• Stores up to 1,554.06 ft3 within an overall footprint of 153.89 sq.ft2
• Easy integration of Modula WMS software with graphical visualization of the tray layout with products location and quantity
• Increased picking accuracy and efficiency with LED bar reading and Dual internal delivery trays
• Easy and intuitive machines with a simple, five-minute learning curve 
• Ample room for future growth