The Challenge

Parts Distribution Center

A service parts operation located on the East Coast of the United States contacted Design Systems, Inc. to develop and manage the consolidation of a multi-site parts distribution operation into a single site operation. The current facility required a warehouse expansion, reconfiguration, and automation to improve efficiency while reducing waste, cost and redundant functions.

The Solution

Design Systems designed a new layout to improve material flow and reduce process complexity by reorganizing material handling equipment and optimizing storage concepts based on order profiles. Warehouse Management System (WMS) opportunities were also identified to further drive optimization within the warehouse.



The DSI Difference

DSI was able to understand the root cause of several inefficiencies and propose changes that optimized the overall operations of the facility in the most valuable way for our client. These results impacted our client positively by:

  • 37% decrease in average cost per order by improving efficiency
  • 572 LPH improvement in picking productivity with addition of “ultra batch” and “goods to person” automation
  • $4.3 Million reduction in manpower
  • 100% client implementation of recommendations on layout, material flow, material handling equipment and storage mediums


  • Warehousing & Distribution
  • Engineering
  • Supply Chain
  • Motor Vehicles

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