AND KENCO
A Kenco Case Study
BLUE BUFFALO
The Blue Buffalo/Kenco
In 2018, Blue Buffalo selected Kenco to run their largest distribution facility in Goodyear, AZ. This 547,000-square-foot, temperature-controlled building facilitates distribution throughout the western United States.
As Blue Buffalo opened new channels, the functions of the facility grew to match, evolving to become a multi-channel distribution center that accommodates its fast growth and new distribution channels.
Today, the Goodyear facility is responsible for distribution throughout the western US; their Direct-to-Consumer offering, Blue at Home; and the creation and fulfillment of their in-store display materials.
Relationship
Overcoming Challenges
6%
Inside the Partnership
About Blue Buffalo
Blue Buffalo creates natural, nutritious pet food for pet parents who believe "if you love them like family, you feed them like family." Blue has designed food for every stage of a pet's life using only the highest quality ingredients.
Blue Buffalo distributes their products to stores throughout the United States and direct-to-consumers through their Blue at Home offering.
In-Store Display Creation
Blue At Home
The facility grew from 40 to over 100 employees, operating across three shifts nearly 24/7. Despite a competitive labor market in Phoenix, AZ—where many similar facilities compete for workers—Kenco successfully scaled its workforce to meet growing demands.
Managing the Labor Market
Managing the Labor Market
Blue Buffalo offers specialized pet food through its direct-to-consumer (DTC) channel, Blue at Home, shipping approximately 400 orders daily across the western U.S. Integrating DTC fulfillment into a traditional distribution center presented challenges, particularly as shifting from pallet picking to each picking increased costs.
Blue At Home
These optimizations streamlined fulfillment while maintaining Blue Buffalo’s commitment to delivering quality pet food.
In-Store Display Creation
Blue Buffalo needed a partner to construct and ship in-store POP displays, a labor-intensive process requiring hands-on assembly and the ability to scale quickly during peak seasons.
Kenco implemented a streamlined process to build and ship over 75,000 displays annually, adapting to seasonal demand fluctuations.
Key solutions included:
Establishing an agile operation that scales up or down as needed
Efficiently managing labor-intensive assembly while maintaining quality
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About Kenco
Kenco provides integrated logistics solutions that include distribution and fulillment, comprehensive transportation management, material handling services, and information technology—all engineered for Operational Excellence. Building lasting customer relationships for over 70 years, our focus is on common sense solutions that drive uncommon value. Visit Kenco at KencoGroup.com.
To optimize operations, Kenco organized a three-day Kaizen event, bringing together floor associates, management, and Blue Buffalo stakeholders. Participants applied Gemba principles and analyzed batching, cycle times, and order flow to identify inefficiencies.
Key improvements included:
Relocating the top 80% of ordered products to a designated warehouse area
Creating a dedicated space for efficient picking, packing, and shipping of Blue at Home orders
This approach ensures Blue Buffalo's retail displays are produced and delivered on time, even during peak demand.
By prioritizing workforce stability and employee well-being, Kenco has built a dedicated team that continues to support Blue Buffalo’s expanding operations.
To attract and retain top talent, Kenco implemented key initiatives, including:
A shift-swapping program to improve flexibility and work-life balance
Efforts to cultivate a positive workplace culture that fosters employee engagement and satisfaction
Since 2018, Blue Buffalo and Kenco have partnered to bring natural, healthy pet food to stores and homes across America.
The results were impressive:
Predictable
96%
Turnover Rate
Attendance Rate
100%
On-Time Shipping
ZERO
Quality Errors
ZERO
Safety Incidences
Labor and Performance Planning
CASE STUDY: distribution
To optimize operations, Kenco organized a three-day Kaizen event, bringing together floor associates, management, and Blue Buffalo stakeholders. Participants applied Gemba principles and analyzed batching, cycle times, and order flow to identify inefficiencies.
Key improvements included:
Relocating the top 80% of ordered products to a designated warehouse area
Creating a dedicated space for efficient picking, packing, and shipping of Blue at Home orders
Key improvements included:
Relocating the top 80% of ordered products to a designated warehouse area
Creating a dedicated space for efficient picking, packing, and shipping of Blue at Home orders
CONTACT US
Let's Connect!