Label Solution Accelerates Order Fulfillment, Generates $1.2MM in Savings | Automotive
1/6/2026
RRD’s custom label solution and automation techniques generate substantial time and cost savings, reduce shipping errors
CHALLENGE
An automotive parts distribution company handling thousands of orders each day was manually processing every order they received, requiring an exorbitant number of hours on a daily basis. Their manual order processing led to additional issues as well, including their workforce’s struggle to keep up with order count, a high percentage of errors, and incorrect product picking.
Although the company had tried to improve their order fulfillment process, they were unsuccessful, hindered by a limited budget and their use of inadequate inventory software systems. The company sought a more streamlined solution to their order workflow as well as a partner experienced in high-volume distribution networks.
SOLUTION
RRD consulted directly with the company’s operations, procurement, and logistics teams, garnering their input on the current order fulfillment process and then producing an actual time study. With this data in hand, they were able to pinpoint the specific barriers to a clean and automated order fulfillment process to reduce touches, decision points, and various manual steps.
To overcome the various pain points, RRD developed a unique label solution featuring multiple sizes of direct thermal pick tickets to help process orders and apply the proper order details via automation. The final solution — including a 4” x 6” option as the pick ticket label — was seamlessly integrated into the company’s distribution network. Orders could now flow automatically and correctly through their multiple warehouses, allowing for same-day order replenishment to each partner, error-free.
RESULTS
By devising and integrating automation techniques into the company’s order fulfillment process in conjunction with direct thermal pick tickets, RRD helped them save both time and resources. RRD's solution:
- Generated more than $1.2 million in annual labor cost savings by streamlining processes and reducing manual effort
- Boosted employee productivity by eliminating 2-3 hours of extra work daily per employee, allowing for reallocation of time to higher-value tasks
- Achieved a 30% reduction in cost per order by automating manual-processing steps — significantly increasing order accuracy and speed
- Improved brand reputation and customer satisfaction by dramatically decreasing order errors, freeing up employees to focus on critical projects and customer engagement