Replacing Manual Processes with Measurable Results
The Challenge
As Comfy Quilts expanded its manufacturing and distribution operations, manual warehouse processes were becoming increasingly difficult to manage.
The company relied on Sage 200 and paper-based picking, with all warehouse data entered and processed manually. Limited stock visibility and frequent errors created inventory inaccuracies, delayed problem resolution, and occasionally resulted in failed customer deliveries.
With stock spread across multiple locations and significant seasonal demand peaks, Comfy Quilts needed a dedicated WMS to improve accuracy, reduce administrative work, and support more efficient distribution and manufacturing operations.
The Solution
Comfy Quilts selected SnapFulfil for its comprehensive functionality, ease of use, and ability to support integrated warehouse operations.
SnapFulfil connected the company's two principal distribution centres within a single WMS, providing a unified view of raw materials and finished goods. Manufacturing was also configured as an internal customer, improving the movement of materials into production.
Following extensive testing and training, both warehouses went live simultaneously ahead of the seasonal peak. The implementation was completed in 15 weeks, with the final operational transition taking just three days.
The Impact
SnapFulfil delivered substantial improvements across Comfy Quilts' warehouse and manufacturing operations.
Manual processing fell by 80%, while administrative work was reduced by 60%. Picking productivity increased by 23%, and putaway performance improved by 29%.
Inventory management became significantly more efficient, with a 50% reduction in associated headcount. Works order lead times also fell from 72 to 24 hours, while finished goods stock loss decreased from approximately 3% to less than 0.5%.
These improvements strengthened operational accuracy, productivity, and service reliability.
