Grocery Retailer Optimizes Warehouse Picking Accuracy and Pallet Stability Through Configuration-Driven Manhattan Active® WMS Enhancements
A 100% configuration-based pick-and-pallet optimization on Manhattan Active® WMS, no custom code, just standard platform features tuned to the way the warehouse actually runs.
Improved picking accuracy and pallet quality
Reduced product damage caused by improper pallet stacking
Eliminated the need for expensive custom code modifications
Engagement snapshot
The challenge
The client's existing warehouse management system faced operational inefficiencies during the picking and pallet-building process.
Heavy meat items were frequently placed on top of lighter products during pallet creation, leading to product damage risks and unstable pallets. In addition, the legacy system lacked the ability to enforce cubic threshold rules, resulting in pallets that were difficult to handle and operationally unsafe.
The business required a more intelligent and scalable picking optimization approach that could improve pallet quality without introducing costly customizations.
What Everest delivered
Everest Technologies partnered closely with the client's operational teams to understand their warehouse workflows and pallet-building requirements in detail.
Using Manhattan Active® WMS, Everest delivered a fully configuration-based optimization solution without introducing custom code.
Solution components
- Picking process optimization
- Improved pallet-building logic during warehouse picking operations
- Reduced risks associated with unstable or improperly stacked pallets
- Configuration-driven solution design
- Delivered a 100% configuration-based solution within Manhattan Active® WMS
- Eliminated the need for custom code development
- Advanced WMS configuration
- Leveraged standard Manhattan Active® WMS capabilities including Residual Cubing Constraint and Pick Location Sequence Configuration
- Enabled intelligent pallet breaks and optimized item placement logic
- Operational alignment
- Worked directly with operational teams to align system behavior with real warehouse requirements
- Ensured scalability and maintainability for future warehouse operations
Approach
The engagement followed a highly collaborative and operationally driven approach.
Everest focused on maximizing native Manhattan Active® WMS capabilities instead of introducing custom modifications. Through detailed analysis of warehouse picking workflows and pallet handling challenges, the team configured standard platform features to address complex operational requirements efficiently and sustainably.
Impact & outcomes
- Improved picking accuracy and pallet quality
- Reduced product damage caused by improper pallet stacking
- Eliminated the need for expensive custom code modifications
- Improved pallet stability and warehouse handling efficiency
- Delivered a scalable and maintainable warehouse optimization solution
Post go-live impact
The client now operates on a standard, scalable, and fully supported warehouse management solution tailored to its operational requirements while avoiding the risks and costs associated with custom-built modifications.
Business impact
- Streamlined warehouse operations and picking workflows
- Reduced operational risks associated with unstable pallets
- Improved long-term maintainability through standard platform configuration
- Enabled a future-ready warehouse management environment without customization overhead
Tools & platforms
- Manhattan Active® WMS
- Residual Cubing Constraint (standard MAWMS feature)
- Pick Location Sequence Configuration (standard MAWMS feature)
Frequently asked questions
Quick answers about this engagement, drawn from the case content above.
The client's existing warehouse management system faced operational inefficiencies during the picking and pallet-building process.
Everest Technologies partnered closely with the client's operational teams to understand their warehouse workflows and pallet-building requirements in detail. Using Manhattan Active® WMS, Everest delivered a fully configuration-based optimization solution without introducing custom code.
Improved picking accuracy and pallet quality. Reduced product damage caused by improper pallet stacking. Eliminated the need for expensive custom code modifications. Improved pallet stability and warehouse handling efficiency. Delivered a scalable and maintainable warehouse optimization solution.
Key tools and platforms included Manhattan Active® WMS; Residual Cubing Constraint (standard MAWMS feature); Pick Location Sequence Configuration (standard MAWMS feature).
Streamlined warehouse operations and picking workflows. Reduced operational risks associated with unstable pallets. Improved long-term maintainability through standard platform configuration. Enabled a future-ready warehouse management environment without customization overhead.
This case study comes from the Grocery & Retail industry, delivered through Everest Technologies' Supply Chain practice.
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