Gorilla Glue is found in almost every supermarket, hardware, big box, and convenience store across the country. These products are wide-ranging, as Gorilla Glue manufactures and distributes 19 different product lines of adhesives, skin-care products, and tapes. Despite double-digit growth, the supply chain wasn’t always efficient. An expansion into new territories and an increase in demand exposed significant inefficiencies within the paper-based process.
One of the main struggles of the supply chain was not knowing the location, type, or quantity of materials. Obviously, this created an inefficient operation and resulted in a lot of wasted time and energy. Inventory control was a significant challenge, as critical information was buried in a stack of paperwork. Employees had to search for various products throughout the warehouse instead of reviewing the amount of inventory on a computer.
Early Automation Tools
Prior to 2015, Gorilla Glue relied mostly on manual data and logistic management information, such as paper spreadsheets, visual observation, and Excel. They were also a long-time user of Microsoft Dynamics GP, as they made an initial attempt at automation by using the ERP’s kitting feature. While this resulted in minimal improvement, it was obvious that the company needed to invest in a much more robust warehouse management solution.
Selection & Implementation Process
Gorilla Glue chose to implement FASCOR WMS to streamline their business operations, as the powerful program is easy to use, and it was able to completely integrate into the Dynamics GP system. Upgrading from one WMS to another was a relatively easy process for data migration, and it only required a few software tweaks.
However, the entire process was a learning experience for everyone involved. This was the first time Gorilla Glue implemented WMS, as they had no prior history or procedures to look back upon. The implementation process forced the company to scrutinize every aspect of their business, create new goals, and develop the most optimal environment for warehouse management going forward.
Much More Than Shipping Glue
Over 30,000 cases are processed for clients ranging from the smallest convenience store to big-box superstores. Such a wide volume of products results in substantial implementation challenges. Each store also has unique labeling requirements, whether it is Walmart, Kroger, Target, or even a small family store. Ultimately, this results in a very complicated shipping process. FASCOR’s technical team was able to configure unique settings to account for such a diverse range of clients while also meeting the various requirements.
Navigating the Supply Chain and Manufacturing Process
Implementation of this warehouse management system resulted in significant improvements in a wide range of areas, such as labor management, work orders, raw materials, and inventory control accuracy. The more streamlined process was also much more efficient, which improved productivity and reduced the amount of scrap.
All of these improvements also allowed management to focus on new product development due to the extra time and resources. Digital tracking capabilities also made it much easier to manage a large amount of data. This is especially beneficial for some products, as they are strictly regulated and require a lot of oversight during the manufacturing process.
FASCOR is relatively simple to learn, as employee training usually took as long as two months, but it was decreased to less than a week. The automation of order fulfillment delivered significant improvements, as productivity increased by 50% with these changes. The system also provides dedicated customer-specific zones to better meet the needs of each client. These innovative changes reduced order fulfillment from 4-6 days to only 24 hours.
Other system optimizations include self-directed put-aways, and electronic replenishment, which improved overall efficiency by 65%. All of these big improvements allowed Gorilla Glue to train staff members for different jobs due to the increase in productivity. Filling additional orders with fewer staff members allowed the company to reallocate resources for new positions while continuing to meet these ever-growing demands.
All of these changes resulted in a 99% order accuracy distribution, which improves customer satisfaction while also making the sales team’s job much easier. Such a high order accuracy distribution rate eliminates the need for physical year-end inventory. The new process reduces the need for wall-to-wall counting, which usually shuts the warehouse down for several days.
Impact on Transportation
Substantial gains were also made in the shipping process. Gorilla Glue also utilizes FASCOR’s transportation management solutions, which is also certified by FedEx, Endicia, and UPS. The system also supports LTL and small parcel shipments to maximize efficiency. FASCOR technology also enables pallets to be strategically placed while also automating cube and weight calculations to streamline the pallet building process. These changes significantly reduce costs for Gorilla Glue and better meets the needs of each customer. Gorilla Glue was also free to pursue more strategic partnerships due to the new levels of supply chain automation.
Real-Time Data Visibility
FASCOR also offers real-time visibility solutions to better track the manufacturing and shipping process. All of this information is easily managed to better handle all types of data and workplace activities. These tools also allow users to monitor the productivity levels of employees and help set goals to improve in a variety of metrics.
Gorilla Glue continues to experience a double-digit growth rate while other departments continue to add new staff members. Investing in FASCOR WMS has allowed the company to keep up with an ever-increasing demand by streamlining manufacturing, warehousing, and distribution to reduce operating costs.