Custom Warehouse Picking Carts for Retail Order Fulfillment – A Case Study

Solution at a Glance

Project Summary

A retailer opening a new distribution center needed custom warehouse picking carts designed for its order fulfillment process. REB collaborated with the retailer to engineer lightweight aluminum picking carts that maximizes picking capacity, improves maneuverability, and reduces freight costs through a knock-down design.

• Products Provided: Aluminum Picking Carts
• Services Provided: Assessment, Custom Equipment Design, Project Management
• Location: Savannah, Georgia
• Industry: Retail Distribution

Concern: Standard Picking Carts Didn’t Match the New Distribution Center’s Workflow

As a clothing and home goods retailer prepared to open its new distribution center in Savannah, Georgia, it needed picking carts capable of supporting a high-volume order fulfillment operation. Employees would use the carts throughout approximately 14,000 square feet of picking space, traveling through 6-foot-wide aisles while transporting

products such as apparel, comforters, bedding, health and beauty items, and other household goods.

The customer initially provided a photo of carts being used at another facility as a reference point. While the existing carts demonstrated the general concept they were looking for, they were experiencing inefficiencies.

The old carts were heavy and bulky, causing employees to take extra time maneuvering the carts through aisles. Additionally, because the carts could only support 4 cartons, employees had to make frequent trips to and from the stock shelves to fulfill orders.

Because the carts would be shipped, minimizing freight costs was also an important consideration.

Solution: Custom Picking Carts Designed for Efficient Order Fulfillment

Rather than recommending a standard picking cart, REB evaluated how the carts would be used throughout the customer’s new distribution center and worked with a manufacturing partner to develop a custom solution.

Discussions with the customer identified a need for a lighter, more maneuverable design that employees could easily push through the facility’s 6-foot travel aisles and around worktables.

After reviewing concepts together, REB and the customer determined that increasing the capacity to three cartons per shelf, six total carton per cart, would allow employees to transport more products during each picking trip without sacrificing the maneuverability they require. The final carts are constructed from aluminum to provide durability while keeping the carts lightweight and easy to move. Each shelf is designed to support up to 200 pounds.

The shelves were positioned at a 10-degree angle to make products easier to see, access, and place during the picking process. The cart’s caster configuration, with two rigid and four swivel casters, provides a balance of stability and maneuverability for navigating aisles and work areas. Together, these features create a warehouse picking cart specifically suited to the customer’s products, facility layout, and workflow rather than requiring the operation to adapt to a standard cart.

Knock-Down Construction Reduced Freight Costs

Shipping efficiency was another important consideration during the design process.

REB worked with the manufacturer to develop a knock-down cart design that could be shipped more compactly than a fully assembled cart. Reducing the shipping volume lowers freight costs by simplifying transportation to the customer’s facility. Once delivered, the carts are assembled onsite.

Project Management

REB coordinated closely with the customer, manufacturing partner, and freight company to design and deliver the carts to the customer for the opening of their new distribution center.

Outcome: Custom Picking Carts Improve Efficiency and Employee Experience

By taking the time to understand the customer’s workflow instead of simply replicating an existing cart design, REB delivered a solution tailored to the operational requirements of the new distribution center. The completed project included the delivery of 15 custom knock-down aluminum picking carts.

Increased Picking Capacity

The final cart configuration increases the customer’s capacity to 6 cartons across two shelves. By allowing employees to pick more items during each trip, the carts maximize productivity while reducing unnecessary travel throughout the picking area.

Improved Maneuverability

The combination of lightweight aluminum construction and the six-caster configuration make the carts easy to control throughout the warehouse. Designed for operation within 6-foot travel aisles, the carts allow employees to navigate around shelving, worktables, and other equipment with greater ease than heavier alternatives.

Enhanced Employee Ergonomics

The 10-degree sloped shelves improve product visibility and reduce the need for excessive reaching when placing or retrieving merchandise. Combined with the lightweight aluminum construction, the ergonomic design creates a more comfortable picking experience during repetitive order fulfillment tasks.

The customer noted that employees were surprised by how lightweight the carts felt and how easily they could be moved despite their large size. This positive feedback reinforced that the design achieved its goal of improving usability without sacrificing storage capacity.

Lower Freight Costs

Designing the carts as knock-down units allows them to be shipped more efficiently than fully assembled carts. Reducing shipping volume helps lower freight costs.

Ready to Improve Your Warehouse Picking Operation?

Every warehouse has unique products, workflows, and operational challenges. Rather than recommending a one-size-fits-all solution, REB evaluates your inventory, picking methods, facility layout, and long-term goals to design equipment that supports greater productivity and employee efficiency.

Whether you need standard picking carts or a fully customized solution designed around your operation, REB’s specialists can help you identify material handling products that improve order fulfillment.

Contact REB today to discuss your warehouse picking application and discover how a custom-designed solution can improve your operation. Call us at (800) 252-5955 or fill out the contact form on this page.