Warehouse Logistics Optimization

United Distribution Services (UDS) is an established presence in the textile warehousing industry, known for innovation in freight and logistics services. Founded in 1995, the privately owned and operated 3PL got its start in the motor freight transportation sector. Consequently, UDS company culture is a standout among competitors as particularly in tune with manufacturer and retailer priorities. 

Supply Chain Planning and Execution

UDS invests significant resources, time, and energy into advising customers to make the right logistics decisions to ensure optimal efficiency and cost savings. The company’s leadership believes in harnessing the power of technology to customers’ advantage, making QSSI an ideal partner. Both our companies ultimately want to liberate clients from supply chain planning and execution, freeing up time and resources for them to focus on primary business functions: manufacturing, marketing, and sale of goods.

Fortune 500 manufacturers and retailers turn to UDS to solve logistics challenges, but so do designers wanting to move their well-structured start-ups to the next level. The company has collaborated for years with experts in warehouse material handling, engineering, and design. 

The goal is to leverage the latest technological development to raise customers to the next level of productivity and competitiveness. QSSI followed a similar strategy when initiating discussions about the effectiveness of UDS processes related to warehouse management, execution, and controls.

To effectively leverage technology, we started by asking UDS pointed questions about their current WMS. Could it provide detailed answers to inquiries, like “How is handling different (or more difficult) this time?” We learned that critical information, such as the precise cost and time investment to fulfill an order, was absent from decision-making protocol.

I had worked with other WMS software in the past and understood the potential for improved CRM. But, ROI for PowerHouse is exponential. With implementation, we went from 10 users to more than 100. You learn PowerHouse, you can now do whatever you want with it, which means my WMS and my company grow together.

Carl Ingargiola, President, UDS
Strategies for Rapid Response to New Customer Demand

For UDS operations to expand exponentially, their WMS needed to support the rapid onboarding of new customers. PowerHouse successfully connects various new revenue streams with a series of warehouse functions and services. UDS now had the ability to configure, reconfigure, and scale its operations (equipment, people, space) in response to evolving customer demands—without expensive modifications to the WMS application.

PowerHouse also supports multiple business models simultaneously—another key strategy employed by UDS to meet increased customer demand. In response to the shift in recent years to Direct-To-Consumer (DTC) shipping, UDS has engineered fulfillment processes and procedures to position its partners to meet their online consumer’s immediate expectations. 

Communication is the key to converting process changes into business opportunities. PowerHouse is a systems integrator for complementary supply chain management software and for all leading e-commerce, marketplace, and carrier software, including shopping carts and customer portals. Therefore, we worked effectively with UDS to handle volume fluctuations flawlessly and at a moment’s notice. Increased flexibility also translated into reduced overhead and the ability to specify a fixed cost per unit.

Tactics Employed for a High-Volume Operation

UDS is an exceptionally high-volume operation, as demonstrated by the 200+ packing stations that keep business booming. The QSSI team partnered with UDS to identify and develop optimal solutions for a full range of customer requirements, from shipping DTC via an e-com site to drop shipping via a carrier. Orders are mapped specific to their type, e.g., flagged as e-com.

UDS is giving its customers the ability to compete with the largest e-com outlets out there. Orders are processed instantly, leaving the warehouse within 12 hours from when the transaction was first initiated.

Ed Troianello, President, QSSI

Through constant reporting, PowerHouse delivers high-level order management and oversight. Quality, actionabledata is made available for informed decision-making. According to the UDS website, automated reporting, among many factors, contributes to the company’s “impeccable fill rates and turns.”

  • Item velocity analysis
  • Pick flow setup
  • Inventory count
  • Location accuracy

Clear order visibility is another important strategy for delivering within a high-volume operation. UDS keeps its customers informed through many PowerHouse capabilities, including transmitting EDI transactions, pushing order status, and tracking information. UDS can also send a branded, yet personalized, email alert, generated by Powerhouse and containing all order information, tracking numbers, and customer service contact information.

Consolidated Dedicated Returns Processing

UDS prioritizes returns processing. The company has dedicated facilities to handle vendors and retailers’ consolidated return services. PowerHouse is an integral part of this process, as well as key to capturing revenue through additional efficiencies and improved customer satisfaction.

A multi-pronged approach ensures the timely reconciliation of return charge backs and consumer credits. UDS leverages as much PowerHouse data as possible to monitor returns volume, eliminate manual data entry, apply credits, and quickly refurbish and transfer goods back to appropriate fulfillment centers. 

PowerHouse captures and monitors data on multiple levels.

  • Return authorization validation
  • Carton level ASN EDI 180
  • Quality inspection
  • Refurbishing to first quality condition
  • Damage and disposal maintenance
  • Trend analysis and advanced BI reporting
A Reliable Partner in Retail Distribution

“Accuracy, accountability, and speed” are the crucial factors in the retail distribution pick & pack environment, according to UDS. The company maintains a 99.98% financial and statistical inventory, achieved through “stringent receiving variance approval procedures, obsessive cycle counting, and utilization of UPC and RFID barcode scanning” (UDS website, 2021). 

All these disciplined procedures are sustained through PowerHouse.

United Distribution Services

Cranbury, NJ

Distribution Center
  • 2,000,000 square feet
  •  Apparel
  • Home goods
  • Manufacturers
  • Retailers
Warehouse Environment
  • Garment-on-Hanger and flat pick & pack fulfillment
  • Just-in-time retail replenishment
  • Direct-To-Consumer shipping
  • Same-day e-commerce fulfillment
  • Full case distribution
  • Retail deconsol/consolidation
  • Domestic transportation
  • Overseas pre-packs
Solutions in the Design
  • Systematic wave modeling
  • Bulk pick line zones
  • Scale counting
  • Pick-to-light
  • Flow racking
  • Automated customized compliance labeling
  • Automated rate shopping
  • Reserve to active replenishment location

Automation-Aware Order Releasing

Origami Owl’s business model is difficult to categorize. Forbes magazine once characterized the privately owned, multi-level marketing custom jewelry company as the 14-year old’s $250M “big idea” (Oct. 2013). Currently, 45,000+ independent sales consultants (“designers”) purchase materials and tools from Origami Owl for product direct sales to customers, primarily via in-house sales parties. What is clear is that this level of thinking outside the [jewelry] box requires that technology evolve and adapt with similar innovation and agility.

Product Customization and Personalization

PowerHouse supplied the logic to make the floor automation in Origami Owl’s warehouses work for the company’s changing requirements, regardless of original design intent. 

Technology needed to evolve to keep pace with the company keeping ahead of developing market conditions, including trends toward product customization and personalization. All aspects of operations needed to work as a single unit to achieve the desired enhancements in materials handling. The “choreography of movement throughout the warehouse,” as described by QSSI’s Chief Product Manager, Rob King, required a turnkey solution.

We considered the entire order journey, more than 1.5 miles of cabling, with the objective of quadrupling production capacity.

A Turnkey Solution for Logistics Automation

PowerHouse enhances the production of automated material handling technologies and concentrates the power of robotics. In effect, it provides the logic for releasing orders using an efficient, business savvy protocol that is specific to the user. 

Origami Owl needed individualized solutions for when, where, and how to sequence various fulfillment scenarios and trigger restocking items. By gaining oversight and control over all moving parts in the warehouse, we were able to affect overall productivity and deliver greater efficiencies. Automation-aware order releasing (as well as automation-aware pick pod selection, path planning, and labor scheduling) helps ensure a productive, cohesive work pace across all work zones.

PowerHouse safeguards that no element within Origami Owl’s warehouse is working in isolation.

For example, scan a box and the system will assess which worker and what route he or she should take, depending on where the remainder of the order is located. Also, no worries about flooding the pick-to-light system, because automation awareness means that the right number of picks will be released into the system in the first place.


Chandler, AZ

Distribution Center
  • 100,000 square feet
  • Custom jewelry design 
  • Apparel and textile
  • Direct sales
Warehouse Environment
  • Complicated sourcing requests
  • Split orders
  • Low minimum order requirements 
  • Combined order and customer processing
  • Just-in-time delivery
Solutions in the Design
  • Embedded TMS
  • Real-time order visibility
  • Scale counting and scan & pack
  • Automated customized compliance labeling
  • Automated rate shopping
Global Supply Chain
  • US
  • Puerto Rico
  • Canada

It’s almost always about managing the release of work. So, you begin by learning how a company does pack & ship—because everyone does it differently, in response to specific programs and compliance requirements.

Russ Schumacher, QSSI’s VP of Applications
Simplified Integration Strategies for Complex Order Management

Origami Owl averages approximately $70 per order. However, multiple highly individualized orders are typically shipped to the same location, at the same time, for the company’s sales events. This reality is a fulfillment challenge experienced by many companies in the creative industries, and the solution is gaining full operational oversight and control.

Who: Origami Owl
What: WMS implementation focused on operational solutions
Where: new state-of-the-art warehouse
When: 3 months leading up to holiday season
Why: optimize $4M already invested in floor automation
Wow: up 45,000 orders avg. per day, down 70% pickers

User-friendly, simplified integration strategies for Origami Owl involved solutions for specific equipment and controllers on industrial networks. Increased oversight and control over automated equipment gave our client distinct advantages.

  • WMS + print & apply labeling—triggers next fulfillment step
  • WMS + handheld devices—enables geofencing and positioning data
  • WMS  + predictive analytics—enhances routing, picking, slotting, etc., processes
Connection between Visibility and Capacity

During a critical period of growth, as Origami Owl ramped up for the holiday season with a brand-new facility, we helped with enhanced interface management. PowerHouse delivered full ERP function integration and directly/indirectly supported enterprise application software. We also supported seamless communication with our client’s EDI, OMS, supply chain management software, and the numerous e-commerce, marketplace, carrier, and customer portals employed by the company.

For Origami Owl, a direct correlation now exists between real-time location visibility (product, assets, people) and a real-time view of warehouse space and storage capacity. PowerHouse’s location capabilities include constant insight into an order’s journey through the entire facility. Floor managers have access to useful data that can be immediately acted upon.

  • Dwell times/congestion analysis
  • Equipment overload mitigation
  • Optimization of underutilized resources
  • Asset tracking 
  • Cross-docking strategies
WMS as the Brain that Drives the Muscle

We built a WMS for Origami Owl that excels with evolving warehouse planning and execution processes. We understood from the start that operations would be routinely impacted by changes originating from variable markets and a global supply chain. Small-scale, transient disruptors, such as influencer driven trends and seasonality, would also be the norm. Operations would need to scale up to meet sales goals.

In response, PowerHouse is made more intelligent with real-time quality data about automation system use and material flow. It is the brain that can adjust to changing conditions—even on an hour-by-hour basis, grouping work for increased efficiency at certain times but also automatically increasing capacity for hot orders or imminent carrier pick-ups.

PowerHouse is effectively thinking for the many systems that comprise the warehouse. For an e-commerce enterprise facing complex order fulfillment requirements, like Origami Owl, this depth of knowledge is a huge competitive advantage.

High-Volume Ecommerce Fulfillment

Inc. magazine twice listed Mud Pie as one of America’s fastest growing private companies (“Inc. 5000”). Woman-owned and woman-led, the innovative wholesale company is known for its popular lifestyle brand and rocket-fueled growth to national prominence. Mud Pie award-winning baby & kids apparel, fashion & accessories, and home pieces are available in 16,000+ specialty retailers and department stores worldwide.. 

Warehouse Automation with ERP, WMS, and WCS Integration

Mud Pie’s move to a totally automated environment was rapid and seismic in terms of operational impact. Just two years before the transition, inventory control was entirely paper based and fulfillment utterly reliant on labor-intensive piece picking.

The company followed a common trajectory for high-volume, fast-paced ecommerce fulfillment environments: sizeable investment in physical automation in response to increased demand—but without adequate ERP, WMS, and WCS integration. 

When QSSI was first engaged, Mud Pie had already implemented robotic systems for piece-picking and packing. PowerHouse brought improved visibility and operational insights to conveyance and sortation, as well as to automated storage and retrieval. In effect, PowerHouse brought the business intelligence for effective automation orchestration.

Adapting to Existing Warehouse Automation

“Steel is steel,” said Russ Schumacher, QSSI’s VP of Application Services, referencing the hard reality of working with an existing complex conveyor system. “You adapt the software to the steel, not the other way around.”

QSSI developed a customized, multi-pronged strategy, involving both people and infrastructure-driven processes, to ensure that Mud Pie would see maximum returns from their significant capital investment.

For example, we made labor more efficient with task interleaving and wave planning. We also equipped people with the right tools for the task at hand. Our team was there for Mud Pie at every step of the transition from pick-and-pass to more complex order picking/restocking methodologies (zone-batch-wave) using tablets and wireless handheld devices with pick-to-light technology.

 In addition, we simultaneously made smart functionality for warehouse controls a priority.

Split Orders and Other Integrated Decision-Making

PowerHouse provides Mud Pie with insights into any number or combination of automation performance metrics (pile-on, pod-station visits, throughput, etc.), but order sequencing decisions ultimately reflect a deeper logic. During PowerHouse implementation and on an ongoing basis, the results of models in different instances are compared with various potential sequential methods. The result is a structured, integrated response. 

A standout scenario for Mud Pie is splitting orders.

Diverse retailers mean diverse customer orders, which can lead to severe inefficiencies in how search and travel tasks are performed. Therefore, it’s critical for the wholesaler to be able to differentiate between oversized, non-conveyable items and conveyable items for warehouse pricing flow. In response, the QSSI team concentrated on the operational logistics of splitting an order. PowerHouse introduced pick pod selection and path planning protocols to improve automation controls. Similarly, pod repositioning protocols address the replenishment process.


Stone Mountain, GA

Distribution Center
  • 250,000 square feet
  • Furniture/home furnishing 
  • Apparel
  • Gifts and novelties
  • Wholesale trade
  • Small independent retailers
  • Big box stores
Warehouse Environment
  • B2B, B2C, D2C 
  • Complicated sourcing requests
  • Split orders
  • Low minimum order requirements 
  • Combined order and customer processing
  • Just-in-time delivery
Solutions in the Design
  • Scale counting and scan & pack
  • Automated customized compliance labeling
  • Automated rate shopping
Global Supply Chain
  • China (manufacturing)

Order picking can constitute 50%-65% of Mud Pie’s operating costs. Processing orders quickly and accurately is a competitive advantage. PowerHouse brings the brains to the machinery that is the company’s lifeblood.

Redesigning a Warehouse for Optimal Efficiencies

Mud Pie has continued to grow its business exponentially. Subsequent warehouse floor modifications and expansions build on the efficiencies originally introduced by QSSI. As part of our next project for the company, PowerHouse supported 9,000 new locations. The new multi-level facility contains 24 zones/pick modules. With Mud Pie, the QSSI team developed and then helped implement a high-bay, narrow-aisle picking concept to maximize the space for a new conveyor system, an impressive 28’ in length. 

Our collaborations also extended to Mud Pie’s manufactures with innovations in packaging. “More conveyable” items inevitably lead to less touches with each induction. With the improvements, 60% to 70% of boxes interface with the conveyor only. This work also resulted in measurable improvements in quality control and speed to resolution.

WCS-Based Automation Visibility

The PowerHouse dashboard is credited with much of the success of the narrow-aisle picking concept. “When you can see all, you can direct all,” said Schumacher. “And, more importantly, you can direct with specificity.” 

The dashboard captures critical information, which means that even in tight spaces it’s possible to follow a serpentine, one-pass packing method. In addition, floor managers can access a graphic of each cart’s contents. RF devices also incorporate graphic displays.

So much more than the sum of its parts, PowerHouse serves as data aggregator and integrator, as well as smart middleware. It eliminated the need for Mud Pie to interface directly to control systems for individual pieces of automation. But, perhaps, most importantly, we introduced a higher level of accountability into the fulfillment process. Warehouse planning and execution are made more intelligent precisely because of the quality information coming from the automation level. 

The Case for a Fully Integrated TMS

We designed PowerHouse for collaboration with shippers, carriers, and third-party programs.

Having a fully integrated transportation management system as part of your warehousing strategy ensures that the various moving components will play well together. Ultimately, you’ll benefit from optimal parcel shipping conditions and the most efficient route management and delivery coordination with retailers.

Supply Chain Synchronization

Work entirely within the PowerHouse environment or incorporate your current TMS. Both options will result in a highly connected supply chain and a full suite of transportation solutions. However, an embedded TMS offers clear advantages for a complex omni-channel order fulfillment environment.

  1. The supply chain execution (SCE) module leverages both WMS and TMS functions.
  2. You can access real-time decision support systems, including dynamic routing and dynamic rating and routing.
  3. Supply chain visibility is available within your enterprise and throughout the extended supply chain.
Enhanced Fulfillment Capabilities

Smart fulfillment is about being flexible but also prepared for fluctuating freight flows. You’ll want collective management capabilities for inter-modal, parcel, less-than-truckload (LTL), air shipments, and more. When traffic fluctuations become the norm so should your capacity for rapid response and adaptation.

  1. Review detailed analytics.
  2. Orchestrate an intelligent transportation plan.
  3. Make sourcing decisions backed by advanced data collection.
Last Mile Logistics

An embedded TMS results in the most accurate distribution network assessments and, therefore, the fastest delivery possible. Warehouse and transportation management capabilities operate within a single execution system, enabling access to TMS planning and tasking functionality at any time during the order fulfillment process. The bottom line: your customers have a seamless shopping experience.

Final Word

The case for a fully integrated TMS will become even more evident as your transportation operations transform into a profit center and competitive advantage. As your customer expectations evolve, so should your TMS grow with your business.

PowerHouse extends your control beyond the warehouse.

WMS+TMS Capabilities
  • customer-specific routing guides
  • TL, LTL, and parcel shipping
  • rate shopping tables
  • truck loading
  • shipment consolidation
  • compliance documentation
Large-scale Efficiencies
  • fast order fulfillment
  • precision control
  • error prevention
  • enterprise-wide business transparency
  • scalability without modification
System Features
  • certified domestic and international small parcel rating 
  • TL and LTL BOL generation 
  • generic carrier rating, labeling, and electronic manifest 
  • unlimited locations and carrier account numbers
  • automated carrier specific time-in-transit routing 
  • parcel tracking and delivery monitoring 
  • process to hold/future shipping 
  • anywhere-to-anywhere rating 
  • multiple package processing and re-cartonization
  • rate shopping by lowest rate and time-in-transit

Rapid Ecommerce Fulfillment

Independent family-owned retailer Rogers Sporting Goods is a formidable player in the sporting and recreational equipment industry. The company is a self-described provider of hunting gear for “the serious outdoor enthusiast” and routinely outsells larger competitors by offering more selection at the right prices. 

Supporting Omnichannel Sales Experiences & Service

Rogers has established a strong brand presence online and through its brick-and-mortar store. Consequently, their warehousing strategy is as agile as their business model. 

One-touch integration across both real and virtual channels gives our client a competitive advantage in a saturated market where suppliers typically try to be everything to everybody. Rogers, in contrast, is recognized globally for giving waterfowlers and hunters exactly what they want and for less. In just a few years, the company experienced substantial growth potential and, in response, initiated a major facilities expansion and an overhaul of order fulfillment processes. 

Location Visibility & Fast Inventory Reconciliation

PowerHouse delivered on a truly integrated platform by supporting clear product location visibility and fast inventory reconciliation, essentials for fast-paced, “real-time, all the time” warehousing. “We’re busy all year round,” explained Brett Patton, Snr. Purchasing Agent. “Lot traceability and live ecommerce are critical, because we’re moving inventory all the time.” 

Upstream & Downstream Data Analysis

As important, PowerHouse gave Rogers the ability to reach beyond their warehouse to gather upstream order information and downstream transportation data. We helped our client decrease dependence on safety stock and streamline open-to-buy budget planning, all while enhancing customer experiences.

“We knew that if we could expand our offerings, we could expand our customer base. Because the QSSI team could think outside-the-warehouse-box about output and potential efficiencies, we had the support we needed to double our business. And, by ‘double our business’ I mean double our output, said Patton.” 

Live in 6 Months! Accelerated WMS Deployment

Rogers moved into a new shell office building and implemented a new WMS in an expanded warehouse facility—all within the course of 6 months. The fast-paced project evolved in phases, each characterized by a new juncture in PowerHouse’s development. Rogers’ WMS went live with the initial set-up of the company’s main warehouse. We then configured and made the retail store operational, followed by the second floor picking mezzanine. 

The capacity to “configure and then reconfigure” in near-real-time is the key to a successful outcome for a complex WMS implementation. “You don’t know what you don’t know,” said Rogers’ warehouse manager, which necessitates demonstrating and testing the system sooner, rather than later.

Smart Warehousing during Company Transition

Significantly, the QSSI team migrated the new warehouse into live mode as the physical components were put in place. Move-in was happening as we built the system and integrated various elements. For instance, we configured the majority of WMS requirements for the mezzanine before it was  built. We also imported inventory into PowerHouse to provide data loading initially for a partial go-live. Our objective was to support business development during  the company’s transition; Rogers’ sales team had accurate data for their webpage. 

Effective Phased WMS Deployment

QSSI adopted an iterative approach to Rogers’ WMS deployment. To connect our client’s various revenue streams, we formulated a series of functions and services, tested the methodology incrementally and frequently, and then evaluated the results based on the latest feedback and evolving business requirements.

According to Roger Saarimaki, Snr. Application Specialist at  QSSI, “Effective phased deployments require constantly monitoring system configurations for changes that can improve efficiency or meet new data requirements.” Rogers’ new dashboard displays order status, work specifics, and any backlogs, which enables operations to respond in real time.

Key Integration Points for WMS Deployment

Integration needed to be in stages to meet Rogers’ ambitious deployment objectives. 

Once the warehouse was set-up, we worked on increasing speed and volume, followed by the integration of the retail store data. The QSSI team started with existing warehouse data. We matched rules to current restocking and picking requirements. As throughput increased, we further configured the locations and tweaked the rules to match. We subsequently addressed the retail store locations in a similar way. Finally, with the configuration of the second floor mezzanine, we could migrate to live as the physical structure was being built.

We based the ongoing changes on new processes to support the host data, as needed. The goal was and continues to be continuous improvement. Ultimately, PowerHouse doubled our client’s previous shipping capacity—without doubling their staff. 

Reducing the Day-to-Day Complexity of Order Fulfillment Operations

PowerHouse agility is also evident in improvements in operational efficiencies and workforce productivity. Rogers can now more easily adapt to shipping variations (ship ready, ship alone, etc.) and count on accurate, precise parcel measurements every time. But, perhaps the greatest cost savings came with the introduction of new processes for reducing time and touches.

Rather than significantly increasing the number of workers on the floor to meet increased demand, PowerHouse made Rogers’ existing labor more efficient. Cartons that don’t require repackaging (or a pack station) prior to shipping can now be picked, labeled, and shipped under one continuous procedure. Carrier compliant labels are printed from a mobile device when the carton is scanned. The worker simply “slaps” on the label and drops the carton at the conveyor to the truck. The fact that the carrier system is fully integrated with the TMS adds another level of seamless execution.

Flexible Order Picking Systems & Methods 

The inherent efficiency of the “slapper” process has resulted in more nuanced responses, e.g., only under certain circumstances is a case pick sent by itself. For Rogers, we configured such criteria in PowerHouse to recognize atypical conditions and to create case picking. Again, there is no need to send the item to a pack station for extra handling. In addition, the item will not incur extra shipping charges.

Similarly, oversized items can lead to uncommon picking scenario configurations. Rogers’ pick module includes reusable totes, but certain items arrive in boxes too big to fit into those totes. As a result, the tote and large carton picks need to arrive at the pack station together to implement the most cost-effective solution, i.e., tote picks packedinside cartons. In these situations, PowerHouse can connect a tote pick with a large carton in the same zone by having the carton “train”  after the tote. The pair move together to the next zone or pack station.

For Rogers, increased flexibility has meant adaptation—the ability to match their WMS to their warehouse environment over time.


Kansas City, MO

Distribution Center
  • 200,000 square feet
  • Double (2-level) pick module
  • Fully RF enabled
  • 40,000+ SKUs
Warehouse Environment
  • Bulk purchasing
  • Low minimum orders
  • Just-in-time delivery
  • Same-day delivery
  • High volume returns 
    and exchanges
Solutions in the Design
  • Identifying labor in/efficiencies—at individual worker level
  • Picking in real-time (interfaces in seconds)
  • Scale counting and scan & pack—for easy picking and re-stocking
  • Automating customized compliance labeling
  • Automating rate shopping—for best shipping rate
  • Order tracking—visibility for customer, too

Warehousing Strategies for Quality Control

Qosina is a leading global supplier of OEM single-use components for the medical and pharmaceutical industries. Through a separate certified division (Qosmedix), the company also distributes beauty tools and accessories to the cosmetic industry. Qosina’s catalogs, which feature thousands of stock items, are widely considered authoritative resources.

High Function Integration with ERP

The integration of PowerHouse with Qosina’s ERP system delivers high functionality above and beyond supply chain execution—i.e., real-time intelligence instrumental in boosting workforce productivity by 30%

Qosina is also experiencing increased visibility at each stage of processing. This has resulted in measurable improvements in Quality Control and compliance documentation, as demonstrated by a 100% success rate with US Customs.

“PowerHouse brought together every aspect of our warehouse processing, under one integrated system,” said Thomas Iavarone, Director Operations at Qosina. “Even for a highly regulated industry like ours, efficiencies were immediate and systemic. We are seeing an average 30% decrease in picking, packing, and shipping times compared to previous years. Also welcomed, the ease with which we can now configure rules and process flows has directly contributed to our company’s growth.”

Directed Work in Real-time

Prior to working with QSSI, Qosina personnel were reliant on tribal knowledge, with valuable information about products, customers, and processes routinely going undocumented. Processing orders involved paper and laptops (no RF mobile devices), which, of course, led to cumbersome procedures for picking, packing, shipping, and restocking. 

Qosina took full advantage of PowerHouse’s configurability. Our software is sector nonspecific and allows for the user to modify the system when responding to operational changes. The capacity to map data, combined with backend analytics, led to significant changes in the order fulfillment process. 

Solutions in the Design
  • Identifying labor in/efficiencies—at individual worker level
  • Picking in real-time (interfaces in seconds)
  • Scale counting and scan & pack—for easy picking and re-stocking
  • Automating customized compliance labeling, e.g., Amazon vs. international importer
  • Automating rate shopping—for best shipping rate
  • Order tracking—visibility for customer, too
Compliance Labeling & Storage

Rules drive efficiencies for warehousing—perhaps, nowhere more evident than with the medical industry. Qosina maintains an immaculate warehouse as per the FDA’s standards for storing pharmaceutical items in safe, optimal conditions. The ability to configure rules and process flows to meet individual requirements of system operation has ensured consistent, dependable regulatory standards compliance.

Strategies for Quality Assurance
  • Clear location visibility—from component to group-of-origin
  • Lot control (no., exp. date, codes, product revisions)
  • Fully RF enabled
  • Fail-safe traceability—image association, color coding
  • Clear differentiation between new/old stock
  • AQL status tracking (pass, fail, quarantine)
  • Packer issued label only when order complete
  • Complete distribution process documentation
  • Audit and recall ready

Ronkonkoma Long Island, NY

HQ & Distribution Center
  • 95,000 square feet
  • climate-controlled
  • ISO certifications
  • medical OEM
  • bioprocessing
  • pharmaceutical
  • cosmetic
  • spa/salon (B2C)
  • 13,000+ catalogue items
  • 8,500+ medical SKUs
  • 40,000+ (avg) pieces 
    per 8’x8’x8’ box
Supply Chain
  • Europe (SRL)
  • Shanghai
  • Taipei
  • Netherlands (3PL partner)
Warehouse Environment
  • Pharmaceutical warehousing FDA CGMP standards
  • SOPs are ISO certification compliant
  • AES filing is Homeland Security compliant
  • Complicated sourcing requests
  • Low minimum order requirements 
  • Combined order and customer processing
  • Just-in-time delivery

Warehousing for a Global Supply Chain

Most companies need business insights, not more data, to expand their operations. To combine information with analysis is to find meaning and a greater understanding of your current situation, with the goal of moving forward. A full stack WMS toolset is a start, but the ability to leverage data from multiple systems (TMS, OMS, LMS, etc.) is a competitive advantage. In the case of our client Standard Fiber, PowerHouse delivered on a number of levels: executive access, customer access, and insight access into their business. With these insights, they extended and then built new revenue channels.

Standard Fiber’s Expansion into New Markets

One of the largest producers of bedding textiles in the world is also a unique model for product development, manufacturing, and distribution. Standard Fiber is the first company in its industry to combine US and UK based innovation with manufacturing capabilities in Asia. Our client offers customers a seamless supply chain experience with access to advanced textile technologies and a premier design-development team, plus the significant cost savings of working with manufacturers in Pakistan, India, and China.

QSSI aligned our client’s warehousing with their ambitious expansion into new lucrative business partnerships.

Early Adaptation in Standard Fiber’s Warehouse

WMS easy scalability and rapid deployment helped our client harness a competitive advantage, specifically, in the bundling of bedding with other products, including mail order mattresses. Achieving this new bundling capability was instrumental in the company’s expansion.

Chris Thornton, EDI/Operations Specialist at Standard Fiber, described the difficult conditions that marked the early days of breaking into a new market. Meeting retailers’ immediate requirements for increased EDI capacity meant implementing the new WMS while dealing with accelerated schedules, high volumes, and complex global logistics.

Thornton credited QSSI with keeping both software and hardware on track and error-free, “QSSI’s people brought a ‘yes, we can do that’ attitude and the timeline for accomplishing the job.”

Smooth Implementation and Rapid Deployment

QSSI helps deliver a seamless customer experience as Standard Fiber scales up to meet increased demand.

Multiple new channels (and new clients) have since been added, but the first “bedding bundle” order was a short 9-week undertaking requiring an overhaul of Standard Fiber’s operations. Rather than significantly increasing the number of workers on the floor to accommodate the additional orders, PowerHouse made existing labor more efficient. We made the floor fully RF enabled and implemented a new process for reducing time and touches.

Cartons that don’t require repackaging (or a pack station) prior to shipping, e.g., bundled mattresses and bedding, can now be picked, labeled, and shipped under one continuous procedure. Carrier compliant labels are printed from a mobile device when the carton is scanned. The worker simply “slaps” on the label and drops the carton at the conveyor to the truck. The fact that the carrier system is fully integrated with the TMS adds another level of seamless execution.

Ultimately, PowerHouse enabled the company to transition to a drop-ship-to-consumer mode while increasing orders by as much as 900% per day.

Custom End-to-End Solutions and EDI Integration

Standard Fiber’s customers expect and receive reliable ecommerce fulfillment support for finished products. Because reputation is built on reliability, it’s important to make continuous improvements in the WMS process and product. You want your WMS to evolve with new business objectives. Chris Thornton, EDI/Operations Specialist at Standard Fiber, put it this way, “When opportunity knocks, you need the backend architecture to take advantage.” He explained, “You want to grow and scale quickly without worrying about system capacity.”

For Standard Fiber, individualized end-to-end solutions have resulted from ongoing collaborative consultation with the QSSI team. For example, we helped the company gain more from their EDI and achieve 100% compliance with their retailers. PowerHouse managed the orders fast enough to handle immense upticks in volume—at times, swelling from 300 orders per week to more than 3,000 per day.

We also integrated PowerHouse with Standard Fiber’s EDI VAN, providing the necessary data for their cloud-based supply chain management software (SPS) to feed their EDI requirements back to customers. PowerHouse leverages the data from multiple systems to “know when to send orders to fulfillment,” said Thornton.

Accessing Information for What Comes Next

For Standard Fiber, we delivered a solution that takes the entire customer journey into account when managing data. Furthermore, this solution is also extensible. Access to a continuous, reliable source of data—such as KPIs at both the facility and enterprise levels—empowers our client to keep making adjustments and improvements in response to an evolving business environment. Wherever Standard Fiber takes their business, we’ll be there to support them.


Las Vegas, NV

HQ & Distribution Centers
  • 4 corporate campuses
  • QC lab (textile testing)
  • 140+ Global Suppliers
  • manufacturers
  • distributors
  • retailers
  • 560,000+ catalogue items
  • 2,500+ SKUs
Supply Chain
  • China
  • India
  • Pakistan
  • Vietnam
  • Brazil
  • Cambodia
Warehouse Environment
  • Textiles warehousing
  • Omnichannel supply chains
  • Complicated sourcing requests
  • Multiple distribution centers
  • Individualized labeling
  • Drop-ship to consumer
  • Just-in-time delivery
Solutions in the Design
  • Fully integrated platform
  • Full visibility
  • Picking in real-time
  • Scale counting and scan & pack
  • Automated customized
    compliance labeling
  • Automated rate shopping