0.01% mis-shipment rate through dedicated large-furniture picking | Meito Inc. Case Study
Dedicated large-furniture picking operation processes 1,200 orders per month with zero mis-shipments
Flow Diagram — Large Furniture, Dedicated Picking, Quality Protection
Dedicated pallets × two-person operation × full-perimeter packaging deliver a 0.01% mis-shipment rate
Project Overview
For a client handling large furniture (sofas, beds, dining tables, etc.), such oversized items are difficult to handle in a standard 3PL warehouse and require picking by two to three workers and delivery by dedicated vehicles. The previous provider had an average mis-shipment rate of 0.8% per month (10 orders/month), driving up re-delivery costs.
The Client's Challenges
- Large items (products over 1 m) are difficult to handle in a standard 3PL
- Re-delivery costs exceeded 30,000 yen per mis-shipment
- Pallet storage resulted in low warehouse space efficiency
- Scratches and dents during picking led directly to customer complaints
Our Proposal & Response
Dedicated large-item zone × dedicated pallets at the Meito Tokyo GLP Logistics Center
We secured approximately 600 ㎡ of the Tokyo GLP Logistics Center's 8,000 ㎡ as a dedicated large-item zone. We introduced 200 dedicated pallets, storing and picking each product on a fixed pallet. For shipping, we standardized full-perimeter bubble wrap + corner guards + stretch film on each product, and provided an integrated operation extending through delivery by dedicated 2-ton trucks.
- 600 ㎡ dedicated zone + 200 dedicated pallets
- Full-perimeter bubble wrap + corner guard packaging
- Picking in two-person teams by 6 dedicated staff
- Same-day / next-day delivery network using dedicated 2-ton trucks
Results
| Item | Before | After | |
|---|---|---|---|
| Mis-shipment rate | 0.8% (10 orders/month) | → | 0.01% (0.1 orders/month) |
| Scratch / dent claims | 5 cases/month | → | 0 cases/month |
| Re-delivery cost | 300,000 yen/month | → | 3,000 yen/month |
| Same-day / next-day shipping rate | 70% | → | 99% |
Client Testimonial
There are truly few 3PL providers capable of handling large furniture. Meito prepared a dedicated pallet for each product, and as a result achieved "no breakage, no mistakes" for us.