When Ed, founder of e-commerce brand KECKS, moved his fulfilment operation back from Cornwall to the Midlands, he faced a major challenge: how to set up an efficient pick-bin system and packaging workflow in a new warehouse. Having grown his brand from his garage into a thriving clothing business, Ed needed flexible, off-the-shelf solutions that wouldn’t break the bank or require long lead times.
The Challenge
- Lack of In-House Expertise: KECKS had minimal experience designing pick-bin layouts or configuring warehouse storage.
- Uncertain Requirements: Without previous in-house operations, Ed wasn’t sure which bin sizes or configurations would best suit his product mix.
- Scalability Needs: The solution needed to accommodate both current volumes and future growth as KECKS expanded beyond underwear into a full clothing range.
The Lesters Packaging Solution
Lesters Packaging Business Development Manager Ash Dickinson led a consultative, “understand more” approach:
- Site Assessment & Planning
Ash and the team surveyed Ed’s new facility to map out available space, product dimensions, and required pick locations (Rows A, B, C, D).
- Off-The-Shelf Pick-Bins
Rather than commissioning bespoke tooling, KECKS opted for ready-made pick-bins in two versatile sizes, delivering immediate functionality, cost savings, and no tooling delays.
- WMS Integration
Leveraging a warehouse management system with handheld scanners, the bins were labelled and slotted into an organised grid, ensuring staff always know exactly where to pick or replenish stock.
- Future-Proof Scalability
The modular bins and rack layouts allow KECKS to add new SKUs or increase stock levels without major reconfiguration, supporting their plans to onboard new customers and expand their product range.
Key Benefits
- Rapid Deployment: Off-the-shelf bins meant KECKS was up and running within days, not weeks.
- Cost Efficiency: No tooling fees and lower upfront investment compared to fully bespoke systems.
- Improved Accuracy & Speed: The WMS-guided pick process reduces errors and speeds up order fulfilment.
- Scalable Design: The versatile bin sizes and modular layout adapt to future business growth.
- Professional Presentation: Neat, uniform pick-bin rows impress visiting clients and help reinforce the KECKS brand.
“I would definitely recommend using Lesters to another business in my position. Whether for pick bins or packaging and storage, it’s been perfect. Many people ask where we got our system – it’s neat, uniformed look sets a great precedent when they visit our facility.”
— Ed, Owner of KECKS
Explore More with Lesters Packaging
Lesters Packaging offers a full suite of services to support businesses like KECKS:
- Learn about our values and commitment to partnership.
- Browse our complete range of products, from pick-bins to bespoke boxes.
- Discover packaging solutions tailored for your industry and operational needs.
Ready to optimise your warehouse and packaging workflows? Visit our homepage or get in touch today to see how Lesters Packaging can help you Deliver More.