Case Studies
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Quality Control +
challenge
A major shoe retailer receives frequent container shipments of shoes, which are then sent from the distribution center to individual retailer stores. When a particular shipment found its way to the company’s retail stores, it became apparent that the shoes had developed mold while in transport from overseas. Not having the personnel, time and space to correct the issue they needed help to find a cost effective time sensitive solution to resolve this and get the product back on the floor for sale.
approach
Each retail location shipped the shoes directly to FRS, where trained and experienced staff inspected each pair, cleaned and retissued each box. Cleaned shoes were returned directly back to the individual store locations directly from FRS’s Facility within a weeks time.
results
Increase ROI; cleaned product can now be sold versus loss of inventory. Improved customer satisfaction; providing quality damage free products to the end customer. The company is able to get all of its shoes quickly back on the retail floor without ever having to ship anything back to or from their distribution center.
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Repackaging for Retail +
challenge
After Eckerd drug stores closed following an acquisition by CVS, an independent company purchased the associated inventory, leaving them with more than 1,000 SKUs that needed to be processed before they could be restocked on another retail floor.
approach
All of the merchandise was shipped directly to Floor-Ready Services. FRS then sorted each product by category, paired similar products, re-priced, repackaged and shipped all material within a matter of days.
results
Facilitated quick ROI by minimizing turnaround time; all merchandise was shipped directly to FRS, saving valuable space at client’s distribution center; the skilled, full-time employees at FRS repackaged all products in a professional manner, ensuring it was available for immediate display on retail floors; client increased productivity and sales without adding to ongoing overhead.
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Missing Parts +
challenge
A national home goods store imported 50,000 turkey fryers that had been specially designed for them. After being inspected by quality control, however, it was determined that two key components were missing from most of the units and needed to be added to make the fryers available before the rapidly approaching Thanksgiving holiday.
approach
The fryers were shipped to FRS, who were given one week to “check, inspect and correct” each one of the 50,000 boxes. A majority of the fryers were missing both a hose, which should have been attached to the fryer, and a special promotional turkey marinade. FRS was able to attach the missing hoses and include the necessary marinade.
results
No interruption to product supply; completed, corrected units arrived at retailers by the original deadline date; FRS handled all shipping and distribution, saving valuable time and space for the client; our dedicated staff inspected and packaged all product in an efficient, professional manner; product was in place at stores for special holiday promotion, guaranteeing a strong ROI.
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A Crisis Solved+
challenge
A worldwide manufacturer/wholesaler that imports merchandise for JIT shipments to Target and Wal-Mart discovered issues throughout a major shipment of merchandise, including missing buttons, stitching inconsistencies and problems with color shading.
approach
Each affected container was shipped to FRS for quality control inspection and processing. After receiving the shipment, FRS opened every box, corrected the variety of issues, remade the pre-packs and returned the inventory to the manufacturer/wholesaler.
results
FRS limited downtime on the affected shipment, quickly correcting and re-shipping the product to major retailers; all deadlines were met, ensuring the client did not default on their original agreement; due to the partnership with FRS, client did not have to invest in any long-term additions to payroll or overhead; project turned into an ongoing partnership between the client and FRS.
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Electronics +
challenge
A global technology leader in electrical products was discontinuing a product line. Discontinued switches were being returned to the company in large quantities. Due to employee constraints, the executive staff (4-6 people at a time), were spending many hours a month dis-assembling the switches to recoup components to be placed back into inventory which would be used in building new products. The executive staff who are both overpaid for that kind of work and are being taken away from their other, more important duties hated doing this and wanted a more efficient cost effective way to accomplish this task.
approach
FRS took over the project. FRS picked up gaylords of switches from the customers facility. Dedicated trained staff dis-assembled the product down to individual components. Each component was counted, documented consolidated into larger quantity bags and returned to their facility.
results
Increased ROI; the need to order new components was decreased due to disassembled product components being returned to inventory. Decreased overhead; executive staff now able to return to core responsibilities. Increased productivity; individual components counted and packaged are more easily tracked and quickly placed back into inventory.
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Recycling +
challenge
A Leading diaper manufacture which holds the No. 1 or No. 2 share position in more than 80 countries is doing their part in sustainable, environmentally friendly practices. Producing 18,000 cores of material per month for diaper fabrication they needed to attempt to recycle those cores and unused material back into the production process versus throwing unused product & cores away. Due to personnel and space limitations they were having difficulty processing the returns in an efficient, cost effective and timely manner.
approach
FRS took over the project; unused cores with material are shipped directly to FRS 137,000 sq. ft. facility. Material is inspected for contaminants and usable material is retrieved, bagged & weighed. Cores are inspected for damage and numbered if reusable. All reusable products (cores & material) are documented and returned to manufacturer's facility to be re-introduced into the processing chain.
results
An increase ROI, approximately $250,000 plus in reusable product annually. Increased productivity; employees now back to doing their core job function. Space; allocated space now available for new inventory which generates revenue not waste.
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Apparel/Labeling+
challenge
A major supplier of outdoor apparel has their products manufactured overseas. Upon arrival in the US and disbursing product to various retailers they started receiving customer complaints regarding the garment “fit”. They realized they needed to have all shipments check to see if the manufacturer followed sizing tolerances/variances per their order. They needed to have each piece measured and documented quickly for manufacturer credit.
approach
The products were delivered directly to FRS facility. FRS’s trained and experienced team measured each piece's (7,200) waist & inseam and checked for overall quality appearance. Each piece was documented and labled with measured sizes, separated and boxed into 1st, 2nd & 3rd quality for easy identification and returned to the customer within 4 days.
results
Increase ROI; shipment fully documented for manufacturer credit. Increased Revenue; 1st quality product able to go quickly and directly back to retailers to be sold. Improved customer service; able to eliminate customer dissatification with providing the correct “fit” the first time.
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Ticketing (UPC) +
challenge
A national jobber/broker was able to acquire 500,000 T-shirts from a manufacturing company that had a major overstock of inventory. After selling the product to a national off-price retailer, the jobber/broker needed the shirts processed and delivered as quickly as possible to the retail chain.
approach
FRS received the shipment directly from the manufacturer. FRS inventoried the shipment, ticketed each piece with the retailers UPC & pricing, created assortments by style, color and size and placed into a floor ready display. FRS then shipped specific store allotments to each individual retail location nationwide.
results
ROI; FRS minimized the time elapsed between the jobber/broker purchasing the shirts and when they were made available for sale. Increased productivity; the retail store location was able to place the products directly on the floor eliminating the need to have store personel ticket and display the product.
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Relabeling/Sewing +
challenge
A major domestic designer receives a shipment of garments from their overseas manufacturer. Upon inspection, the designer realizes the “care and content” labels were incorrect. The garments are silk, but the labels said polyester, and the care instructions are completely wrong. The company’s existing staff was already doing their regular production and didn’t have the resourses available to correct this issue in an efficient and timely manner.
approach
The garments were shipped to FRS, where the labels are removed by hand. The correct labels were re-sewn onto the garments, which were then completely re-packaged (hung & placed in individual plastic bags) for retail and shipped back to the distribution center within 5 business days.
results
ROI; The designer’s garments, with the correct labels, were available for retail after a very quick turnaround. Increased productivity; existing staff was able to continue their core efforts, without having the need to divert their attention to an out of process crisis.