Logistics ops ·

Medifast streamlines warehouse pick-and-pack with Blue Yonder Warehouse Management

The problem

Medifast employees hand-selected boxes and two employees were needed to scan, weigh, and apply shipping labels, causing excessive void fill use, repacking delays, and wasted labor from double-touching products through totes before they reached the shipping box.

Workflow diagram · grounded in source
1
Load product data into WMS
Integration
Product weights and dimensions are loaded into the Warehouse Management System.
▾ source quote
“the company has the product weights and dimensions loaded into the WMS”
2
WMS selects box and prints label
Routing
The system chooses the right box and applies the shipping label on the front end before the order is picked.
▾ source quote
“The system can choose the right box and apply the shipping label on the front end before the order is picked”
3
Direct pick into shipping box
Output
Products go right into the shipping box instead of into a tote first, reducing double touches and wasted labor.
▾ source quote
“Products go right into the shipping box, instead of into a tote first reducing double touches and wasted labor”
4
Direct-to-work queue assignment
Routing
Employees work from a direct-to-work queue in warehouse management in real-time.
▾ source quote
“With the direct-to-work queue in warehouse management, Medifast employees are working in real-time”
Reported outcome

Medifast employees now work in real-time from a direct-to-work queue, eliminating double-touch picking, reducing overall time to ship and labor costs, and increasing margin.

Reported metrics
Employee productivityimproved employee productivity
Headcount optimizationheadcount optimization
Double working pick and packreduces double working a pick and pack
Time to shipreducing overall time to ship
Show all 7 reported metrics
employee productivityimproved employee productivity
headcount optimizationheadcount optimization
double working pick and packreduces double working a pick and pack
time to shipreducing overall time to ship
labor costsreducing... labor costs
marginincreases margin
wasted labor from double toucheswasted labor
Reported stack
Blue Yonder Warehouse Management
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Source
https://blueyonder.com/customers/medifast
Read source ↗

Frequently asked questions

What did this team achieve with this AI workflow?

Medifast employees now work in real-time from a direct-to-work queue, eliminating double-touch picking, reducing overall time to ship and labor costs, and increasing margin.

What tools did this team use?

Blue Yonder Warehouse Management.

What results were reported?

Employee productivity: improved employee productivity; Headcount optimization: headcount optimization; Double working pick and pack: reduces double working a pick and pack; Time to ship: reducing overall time to ship (source-reported, not independently verified).

How is this logistics ops AI workflow structured?

Load product data into WMS → WMS selects box and prints label → Direct pick into shipping box → Direct-to-work queue assignment.

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