Challenge

Relocating and combining the brand’s corporate headquarters and distribution center into a single new facility capable of supporting increased capacity

Requirements

• Facility design and material handling equipment that can accommodate aggressive growth
• Rapid deployment without disruption to current operations

Results

• Increased product processing rate by 300%
• Reduced labor requirements by 30%
• New facility deployed ahead of schedule without interruption in service

Challenge

Accommodating multiple tenants with varying needs and rising storage requirements

Requirements

• DC design and material handling systems focused on increased efficiency and capacity
• Rapid, cost-effective redesign that meets service expectations without disruption to current operations

Results

• Implemented a DC design on a strict budget that met service levels without impacting facility operations
• Doubled two tenants’ volumes in size within a 30% smaller footprint

Challenge

Manual, paper-based distribution operations unable to accommodate the manufacturer’s massive annual growth and increasing customer demands

Requirements

• Modern material handling systems and processes focused on increased capacity and efficiency
• Multi-phased implementation approach that does not impact current shipping operations

Results

• Reduced inventory carrying costs by improving inventory accuracy, lot control and traceability
• Increased distribution order processing capacity by more than double
• Reduced order processing lead times from three days to less than one day

Challenge

Current distribution operations unable to support rapid growth and evolving product requirements

Requirements

• Material handling systems that enable the company to maintain high order accuracy and on-time shipments while minimizing labor costs
• Flexible solutions and DC design that are scalable for growth and capable of adapting to meet changing product needs

Results

• Designed and implemented a highly automated $17M facility
• Deployed high-speed material handling systems that increased throughput and accuracy and decreased labor requirements

Challenge

Current facility unable to accommodate the retailer’s continued growth in online and store sales

Requirements

• DC redesign focused on increased capacity and efficiency
• Material handling equipment and IT infrastructure capable of supporting multiple sales channels

Results

• Designed and implemented an upgraded multichannel facility to meet the retailer’s distribution requirements for at least three years
• Increased storage capacity by more than double
• Improved productivity by 20%

Challenge

Inefficient, labor-intensive fulfillment operations unable to accommodate strong growth

Requirements

• Facility design and material handling systems focused on increased efficiency and capacity
• Multi-phased implementation that does not disrupt current operations

Results

• Designed and implemented a 120,000-square-foot facility without impacting ongoing operations and customer service
• Increased efficiency of pick and pack processes by nearly 50%
• Achieved 30-40% increase in unit volume

Challenge

Outdated operations and systems producing massive inefficiencies and capacity constraints at the retailer’s distribution centers

Requirements

• Robust material handling equipment capable of supporting strong growth
• Upgraded facilities focused on increased efficiency, capacity and productivity

Results

• Consolidated four DCs into a single greenfield West Coast facility
• Achieved a 20% increase in throughput at two existing DCs
• Increased productivity and efficiency by 30%

Challenge

Designing and implementing an efficient distribution center for a major online retailer

Requirements

• Advanced material handling equipment capable of supporting a variety of product types and volumes in an online environment
• DC design and operations that enable the company to increase efficiency and meet throughput requirements with a five-year plan

Results

• Implemented a flexible solution with the ability to handle changing product requirements
• Increased volume by over 150%
• Improved operational efficiency, appreciably reducing headcount

Challenge

Outdated facility unable to meet future requirements of a central distribution center

Requirements

• DC redesign focused on increased capacity and space utilization
• Flexible material handling equipment capable of meeting varying SKU requirements

Results

• Designed and implemented an updated facility to meet the company’s long-term projected volumes and new product lines
• Tripled order processing capacity
• Increased storage capacity by more than double