Warehouse

Our Socially Distanced Office Space

When this pandemic began, one of the first things that we did was to require that all non-warehouse staff work from home. As time went on, and as New York has loosened its restrictions, we’ve moved all of the staff back to the warehouse and us owners have resumed our regular rotating schedule. Even with our rotating schedule, our office wasn’t quite spaced out well enough to provide everyone a socially distanced 6 ft between desks. Part of the problem is that when we built… Continue reading

7/7/20

Our Warehouse Package Cutoff System Wasn’t Designed For This, But It Is Saving Us Right Now

Every once in a while you win one by accident. About a year and a half ago I wrote a post A New Tool for Managing Busy Warehouse Days where I described a system that we built for handling volume spikes in our warehouse, both planned and unplanned. From that post: On our back-end we’re able to set a package cutoff for any upcoming shipping day. We use historical data along with staffing information to aid us in picking the number. Once our shipping queue… Continue reading

5/28/20

A Video Overview of Our Pick & Pack Process

My business partner Greg was recently interviewed by The Rag Company at our newly renovated warehouse about our pick and pack process. One of the main components covered is our packing slip route optimization that I wrote about in-depth recently. I wasn’t in the office that day to meet them, but we were very grateful to have the opportunity to host The Rag Company. Their crew did an A+ job with this video and a few other ones. As you can read in the video… Continue reading

7/1/19

Packing Slip Routing Optimization: How Our Expanded Warehouse Made Our Packing Slips Obsolete & How We Improved Them

We recently completed our warehouse renovation just in time for Memorial Day. I snapped a quick photo of the new space, which you can see we’re already utilizing: The big advantage of this new space is that we have almost 6,000 sq-ft more to dedicate to products. That means we can space products out better and reduce the usage of separate overstock areas. It also keeps the aisles and shelves more organized. Deciding on the new shelving layout and product flow was pretty easy. We… Continue reading

5/30/19

We’re Expanding Our Warehouse Again!

In 2017 we knocked down a wall in our original 5,000 sq-ft warehouse and expanded to roughly 10,000 sq-ft. At the time, the thought of needing more space anytime soon was laughable. However, after two big spring/summer seasons, we began to consider the idea of expanding again. Then after talking with our industrial park and learning that there was some space available, we decided to jump on the opportunity. Construction started earlier this week, and yesterday the wall came down separating the two spaces. It… Continue reading

3/14/19

A New Tool for Managing Busy Warehouse Days

Typically our busiest shipping day of the week is Monday. This is pretty intuitive, given that we’re shipping out orders from Friday afternoon through our 1 PM same-day cutoff on Monday afternoon. Three-day weekends during our peak season, such as Memorial Day, Labor Day, and (sometimes) July 4th, when we’re also typically running a big sale, are even busier. And as we’ve grown over the years, those peaks have become even greater proportionally. Essentially, it’s easier to find growth during a big sale in peak… Continue reading

1/24/19

Memorial Day Madness – When Systems Get Pushed to the Limit

Typically, I don’t spend a ton of time within our day-to-day operations. More so than anyone else at our company, I’m usually working on developing features that will improve our customer experience and/or save us time and mistakes. Most of the time I’m a few steps ahead, meaning I’m creating/fixing/improving something that’s not quite a problem yet or that we probably don’t need yet, but that we think we will in the future. Having this mentality has largely saved us from ongoing total chaos as… Continue reading

5/30/18

Warehouse Renovation Complete!

During the last week of 2016 construction wrapped up on our warehouse renovation. It took us a few weeks afterward to complete our rearrange and redesign, but now we’re finally operating at full capacity in the new space! The photo above is a look at the space that we’re currently using for packing and shipping orders. Our total space doubled from around 5,000 sq-ft to around 10,000 sq-ft. For packing and shipping, we’re essentially using the same inventory zone system I detailed in 2010, with… Continue reading

2/21/17

We’re Literally Under Construction

Over the years we’ve improved a lot of things about our warehouse since first moving in back in 2008. We’ve gone from using a 3G hotspot to having a high speed connection, we’ve remodeled and improved our small office, added better lighting, and of course upgraded our horrible heating system. The space has gone from pretty run down to a decent space, however it’s still been the same space and recently we’ve been feeling really limited by our ~5,000 sq-ft. We don’t have the space… Continue reading

10/6/16

The Great Warehouse Flood of 2014

Early on a Monday morning in January of 2014 I received a phone call from our warehouse manager. Typically early morning phone calls mean that something is wrong, but usually it’s nothing like this. When our employees arrived that morning they were greeted by a flooded warehouse. Parts of the warehouse were in several inches of water, and most of it was in some sort of standing water. It looked like this: And this: Immediately they started photoing everything, which was a huge help with… Continue reading

2/10/16