Johnson & Johnson Vision Care Manufacturing Plant: Designed for Speed ​​and Precision

J&J Vision Care – Jacksonville, Florida

Cut: 200,000 square feet
Some products: Vision care products
References : More than 30,000 SKU references and growing
Debit: 10,000 orders per day in worldwide distribution
Changes: 24/7 operations
Employees: 200+

The J&J Vision Care facility in Jacksonville uses a variety of order picking technologies to fill orders based on the travel speed of the SKUs involved. Here is how the product circulates in the installation.


The warehouse is adjacent to the J&J Vision Care manufacturing plant and receives incoming finished products in the area (1) on a 24/7 schedule. Raw materials arrive at the back of the factory and are transformed into finished products which are then transferred by forklift to a quarantine area prior to a quality control inspection. Once the new product is approved, it is received into the Warehouse Management System (WMS), prepared for entry into stock, and available to fulfill customer orders.


The old WMS chooses a storage location in the pallet racking storage area located in the finished product warehouse (2). Lower level locations are designated for picking up crates from fast movers; the upper levels are designated for reserve storage. The forklift operator scans the pallet in the appropriate storage location.


Manual flow racks support picking processes in the A-frame picking area (3) and pick-to-light selection modules (4). When an inventory slot reaches its min / max level, a replenishment signal is sent to the WMS. Associates the boxes with a stock preparer in the finished product warehouse (2) then insert the crates onto the conveyor system. The cases are then routed and sorted to the correct area, where an associate scans a case into the appropriate location in the flow rack.


SKUs are assigned a selection technology according to their speed: the fastest SKUs go to frame A (3); then pick-to-light (4) then to the new automated storage and goods-to-person technology (5). A new product launch, for example, will start in frame A (3) then switch to pick-to-light (4) as demand stabilizes and new products exceed current demand. J&J Vision Care uses an optimization tool that examines the order volume for each SKU and recommends replacement as needed.

Execution of orders:

All commands start the same way. An order bin is electronically mated to an order via barcode scan and is then fed onto the conveyor system.

The WMS analyzes the order, then directs the bin through the facility. The first stop is the pick-to-light pick mezzanine (4). The VLM selection area, which only manages a small number of references, is also located in the light selection area. Once all of the items in an order are picked from that area, a robot picks up that bin and empties it into the main bin which will go to another picking area where associates use wrist scanners for hands-free picking. If necessary, the tote moves next to the A-frame (3), where the items are automatically dropped into the tote. Finally, he goes to the new personal goods picking station (5).

In the field of personal property (5), the bins are picked up by mobile robots inside the storage units and then transported to the picking station. There, the associate is directed by the light to one of the four quadrants of the tote. The associate chooses the correct number of parts and places them in the order bin. The order is now ready to be packed.


Once the order has been picked, it is sent to one of the packing stations in the order packing area. (6). At this point, each item is scanned to verify that the lot number and SKU are correct. Once the WMS has verified that the order is complete and correct, a shipping label is printed and affixed to the shipping box. It is then sealed and placed on the shipping conveyor and delivered to the output shipping area (7). From there, the box is routed to the correct lane for UPS or FedEx shipping, depending on the location of the delivery.

A crossdocking operation is used for some large retail customers who order for several hundred stores, forcing J&J to pack orders by store. In these cases, a shipping carton may contain 30 to 50 orders that are shipped overnight to the retailer’s distribution center. There the checkouts are opened and the individual orders are sorted by store.

System providers

System and conveyor integration: Bastian Solutions
Automated storage and preparation of goods in person: Operating company
Order preparation solution and A conveyor: SI systems
Spiral conveyor: AmbaFlex
Barcode reading: Cognex
WMS: System inherited from J&J, sampling system from SI Systems
Mezzanine: Wildeck
Forklifts: crown

About the Author

Bob Trebilcock Bob Trebilcock, Editorial Director, has covered material handling, technology, logistics and supply chain topics for almost 30 years. In addition to Supply Chain Management Review, he is also editor-in-chief of Modern Materials Handling. A graduate of Bowling Green State University, Trebilcock lives in Keene, NH. He can be reached at 603-357-0484.

Leon E. Hill

Leave a Reply

Your email address will not be published.