Case Study: Apparel Manufacturer doubles facility capacity and cuts labor costs with Bastian Solutions' AutoStore system

Apparel manufacturing Company - Customer Case Study

Apparel manufacturing Company, a fast-growing specialty apparel retailer, faced the prospect of a costly move or building expansion to increase storage capacity while also needing to reduce variable labor costs and improve order picking speed and accuracy. Bastian Solutions was engaged to address these challenges and deployed an AutoStore robotic goods-to-person system combined with Exacta Warehouse Control System, put-to-light stations and a ZiPline accumulation conveyor to optimize e-commerce fulfillment.

Bastian Solutions’ AutoStore solution more than doubled the facility’s storage density—yielding 2.25 million AutoStore storage units for every 1 million units of prior static racking—allowing the Apparel manufacturing Company to remain in its existing building. The implementation cut manual walking (previously about 1.5 miles per picker), reduced temporary labor and variable operating expenses, improved ergonomics and order accuracy via Exacta WCS and put-to-light integration, and streamlined flow to shipping with the ZiPline conveyor.