The Challenge:

National Automotive Parts Retailer Increases Capacity of Regional Distribution Center

A national retailer of automotive aftermarket parts needed to expand one of their major regional distribution centers. The facility had to continue to service existing stores, as a new system would be implemented to increase worker productivity, and provide capability to meet future needs.

To accomplish these goals, the new system layout had to concentrate forward picking, minimize walking, and allow for efficient replenishment. Conveyor had to be able to handle both totes and cartons.

The Solution:

The existing building was expanded to use three picking modules, each three levels high, for conveyable product. Slow-moving parts are housed in shelving modules, while fast-moving parts are located in fast-pick carton-flow and pallet pick modules. Oils, paint, and chemicals are housed in modules in a special storage room.

Conveyors move orders picked into recyclable totes, which are then directed to the correct shipping lane by high-speed sorters.