Case Study: NewAge Products Monee, Illinois

From Zero to Full Production with P4 Warehouse, SAP B1, and EDI

Overview

NewAge Products, a leader in premium home organization solutions, set out to establish a high-efficiency distribution center in Monee, Illinois. This strategic location was chosen to optimize logistics efficiency and accelerate order fulfillment. To achieve operational excellence, NewAge partnered with Barrdega to implement P4 Warehouse, a modern Warehouse Management System (WMS) that replaced the outdated Extensiv software. This transition provided NewAge with a cutting-edge advantage through enhanced automation, real-time visibility, and improved scalability. The case study details the transformation from a newly constructed warehouse to a fully operational logistics hub integrated with SAP Business One (SAP B1) and Electronic Data Interchange (EDI).

Challenges

NewAge faced several key challenges in launching this facility:

1. New Facility Setup – The warehouse was built from the ground up, requiring the complete implementation of operational workflows, equipment installation, and software integration without any pre-existing infrastructure.
2. Technology Integration – Seamless connectivity between P4 Warehouse, SAP B1, and EDI was essential to prevent inefficiencies, data inconsistencies, and processing delays.
3. Wireless Infrastructure – A robust Wi-Fi network was needed to ensure real-time data communication across all warehouse operations.
4. Hardware Deployment – The selection and configuration of Zebra mobile computers, printers, and barcode scanners were crucial to improving warehouse productivity.
5. Operational Efficiency – From receiving to shipping, all workflows had to be optimized to prevent order processing bottlenecks and fulfillment delays.

Solution Implemented

Barrdega executed a comprehensive implementation strategy, transforming the warehouse into a high-performance distribution center by addressing the following areas:

1. P4 Warehouse Implementation

• Automated Inventory Management – Enabled real-time tracking, reducing stock discrepancies and eliminating stockouts.
• Optimized Order Fulfillment – Improved picking, packing, and shipping processes to improve speed and accuracy.
• Seamless SAP B1 Integration – Automated financial reconciliation and inventory updates, minimizing manual errors.
• EDI Connectivity – Ensured fast and accurate data exchange between suppliers and retailers.

2. SAP B1 Integration

• Automated Data Flow – Enabled real-time synchronization of purchase orders, invoices, and inventory records, reducing manual intervention.
• Financial Accuracy – Improved financial tracking, cash flow management, and compliance reporting.

3. Wireless Infrastructure Deployment

• Ruckus Wi-Fi Installation – Provided stable, high-speed connectivity, ensuring seamless warehouse operations.
• Enhanced Mobility – Enabled warehouse staff to access real-time data from any location within the facility, reducing delays.

4. Zebra Hardware Deployment

• Zebra MC9300 Mobile Computers – Improved picking accuracy and transaction speed with real-time barcode scanning.
• Industrial Printers – Ensured fast and reliable barcode labeling for inbound and outbound shipments.
• Seamless Hardware Integration – Optimized communication between P4 Warehouse and Zebra devices for enhanced workflow efficiency.

5. Warehouse Operationalization

• Comprehensive Staff Training – Ensured employees were proficient in using P4 Warehouse, SAP B1, and Zebra hardware.
• Standardized Processes – Implemented best practices for receiving, storage, picking, and shipping to maximize efficiency.
• Performance Monitoring – Introduced reporting tools to track key performance indicators (KPIs) for continuous improvement.

Results

By addressing these challenges effectively, NewAge achieved significant improvements:

• Operational Readiness in Record Time – The warehouse transitioned from an empty facility to full-scale operations within the planned timeline, reducing ramp-up time by 30%.
• Seamless System Integration – P4 Warehouse, SAP B1, and EDI worked cohesively for streamlined inventory and order processing, cutting order processing times by 25%.
• Enhanced Productivity – Zebra MC9300 mobile computers improved picking accuracy by 99.5%, reducing errors and increasing order fulfillment speed.
• Reliable Wireless Connectivity – Ruckus Wi-Fi ensured uninterrupted real-time data communication across the warehouse, minimizing delays in scanning and inventory updates.
• Scalability for Future Growth – The implemented solutions provided a strong foundation for handling increased order volumes, positioning the warehouse for continued expansion.

Conclusion

The successful implementation of P4 Warehouse, SAP B1, and EDI at NewAge Products' Monee, Illinois warehouse demonstrates the power of strategic digital transformation. With Barrdega's expertise, the facility evolved from an empty space to a high-efficiency logistics hub, reinforcing NewAge's commitment to operational excellence and customer satisfaction.

About Barrdega

Barrdega specializes in warehouse and logistics solutions, providing advanced technology and expertise in WMS, ERP integration, and automation. With a proven track record of transforming warehouses into high-efficiency operations, Barrdega continues to drive innovation in supply chain management and logistics technology.