Imagine thousands of contact lenses traveling daily from production lines to consumers worldwide with remarkable efficiency and precision. Behind this seamless operation lies not just advanced manufacturing techniques, but a meticulously designed logistics system. Johnson & Johnson Vision's Jacksonville factory stands as a paradigm of this operational excellence, employing multiple picking technologies optimized for different product velocities to perfect its order fulfillment process.
Seamless Integration: Receiving and Storage
The Jacksonville facility's warehouse sits adjacent to its production area, creating uninterrupted workflow. A 24/7 receiving system ensures continuous flow of finished goods into the inbound finished goods area (1) . Meanwhile, raw materials arrive at the factory's rear, where they're transformed into finished products before forklifts transport them to quarantine for quality control inspection.
Once new products pass inspection, their information enters the Warehouse Management System (WMS) , completing pre-staging preparations before immediately entering customer order fulfillment. The WMS intelligently selects optimal storage locations based on product characteristics. The pallet rack storage area (2) positions fast-moving products on lower levels for quick access, while higher locations hold reserve inventory to maintain supply chain stability.
Precision Replenishment: Fueling Efficient Picking
To support high-speed picking operations, the factory employs multiple replenishment strategies. Areas like the A-frame picking zone (3) and light-directed picking modules (4) rely on manual flow racks for restocking. When inventory dips below preset minimums, the WMS automatically triggers replenishment requests.
This hybrid manual-automated approach ensures picking zones remain fully stocked while adapting flexibly to product demand fluctuations. Real-time WMS monitoring and intelligent scheduling minimize human error during replenishment, maximizing efficiency.
Dynamic Resetting: Optimizing SKU Placement
Johnson & Vision employs a dynamic resetting strategy that continuously optimizes picking efficiency by assigning SKUs to different technology zones based on velocity. Fastest-moving SKUs go to the A-frame (3) , followed by the light-directed picking area (4) , then the new automated storage and goods-to-person technology zone (5) .
The company uses optimization tools to regularly analyze each SKU's order volume and recommend reassignments. This data-driven approach ensures optimal placement for maximum picking efficiency and minimal operational costs.
Multi-Technology Order Fulfillment
All orders begin identically: a tote scans its barcode to electronically link with an order before conveyor transport. The WMS analyzes each order and routes totes through appropriate picking zones.
The journey starts at the light-directed picking mezzanine (4) , where robots consolidate items into master totes if needed. These then proceed to the A-frame (3) where products automatically drop into totes, before final processing at the new goods-to-person stations (5) .
In the goods-to-person area, mobile robots retrieve storage containers and deliver them to picking stations. Workers, guided by light indicators, select items from four container quadrants before placing them in order totes for packaging.
Quality-Assured Packaging
Completed orders move to the order packaging area (6) where each item undergoes barcode verification. The WMS confirms order accuracy before printing shipping labels. Sealed boxes then travel via conveyor to the outbound shipping area (7) for UPS or FedEx routing.
For major retail clients with hundreds of store orders, Johnson & Vision employs cross-docking operations where shipments containing 30-50 store-specific orders travel overnight to retailer distribution centers for final sorting.
Operational Excellence in Detail
The factory's meticulous attention to detail extends beyond core processes. Warehouse layouts optimize human-machine collaboration, minimizing unnecessary movement. A preventive maintenance program ensures equipment reliability, while comprehensive staff training develops highly skilled operators capable of maintaining peak efficiency.
Innovating for the Future
Facing evolving market demands, Johnson & Vision continues exploring artificial intelligence and big data applications to further enhance inventory management, demand forecasting, and order fulfillment. Sustainability initiatives include eco-friendly packaging and optimized transportation routes to reduce environmental impact.
Industry Lessons
The Jacksonville facility demonstrates how manufacturing excellence requires integrated supply chain design, technological adoption, workforce development, and continuous innovation. Its success offers valuable insights for manufacturers navigating today's competitive landscape.
The Smart Manufacturing Horizon
As Industry 4.0 technologies advance, Johnson & Vision's operation previews manufacturing's intelligent, automated, and interconnected future. The facility's evolution suggests how emerging technologies will create increasingly efficient, adaptable, and sustainable production ecosystems worldwide.