The Challenge

A service parts operation located in the Midwest of the United States reached out to Design Systems, Inc. for supply chain and material flow expertise in support of their acquired brownfield facility. This engineering support would encompass a new warehouse expansion, packing operation layout, and receiving / shipping dock operation.

The Solution

The team at DSI Analyzed current layouts and designed warehouse material storage for increased capacity and efficiency. These solutions implemented implementing Best in Class material flow and lean processes, primarily targeting putaway and outbound shipping. The team also saw areas for improvement for a Warehouse Management System (WMS) and recommended the right one for our client.

These solutions resulted in the following outcomes:

  • 100% implementation of recommendations by client
  • Automation / conveyors decreasing material handling headcount, reducing travel time and improving safety
  • Implementation of layout design improving material flow and reducing complexity in warehouse processes while incorporating 15% year over year growth rate over 5 years
  • 60% reduction in man-hours required to complete tasks by deploying systematic locations
  • Outbound shipping transformation via WMS configuration.



The DSI Difference

The Design Systems difference can be portrayed by our understanding of our client’s unique needs. DSI worked closely with management to arrive at actionable solutions that made sense for their goals. These solutions helped to improve the clients original goal of increasing throughput on their warehousing operations – but also yielded other benefits to improve operations.

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

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