Document Security Drives Need for Improved Order Fulfillment Accuracy
Case study of Merrill Corporation replacing manual picking with Intelligrated Voice to achieve 99.90% order accuracy and 45% throughput gains for regulated, confidential documents.
Merrill Corporation, a 3PL handling complex, confidential documents for healthcare and financial clients, faced rising SKU counts and strict regulatory requirements that exposed errors in manual paper-based picking. The company implemented Intelligrated Voice across sales order picking, production order picking, cycle counting, replenishment, and stock transfers. Results included a 65% reduction in picking errors, 45% throughput increase, 50% staffing reduction in equipped areas, and training time cut from two weeks to under one hour.
Voice-directed workflows raised order accuracy from 99.73% to 99.90% for regulated documents
Throughput increased 45%, exceeding the 30-35% target, while cutting staffing needs by nearly 50%
System supports configurable validation levels for novice versus expert workers
Training time reduced to one hour with real-time coaching and audio logging features
Voice expanded beyond initial picking to cycle counts, replenishment, and slot verification
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