Case Study: Garmin achieves dramatic labor reduction and scalable automated distribution with Bastian Solutions

Garmin - Customer Case Study

Garmin engaged Bastian Solutions to modernize material handling at its Olathe, KS distribution center with the goal of minimizing manual touches, centralizing remaining manual activities, and supporting an aggressive annual growth target of 30% for five years. Bastian Solutions proposed a comprehensive automation scope including its ExactaWCS warehouse control system along with conveyors, sorters and related material handling equipment.

Bastian Solutions installed roughly 3,500 ft of Hytrol conveyor, two ProSort 100 slat shoe sorters, roller conveyors, shipping and pack stations, Interlake racking (8,000+ pallet locations), Mettler‑Toledo checkweigher, Transnorm chutes and its ExactaWCS/PLC/HMI control, plus other automation elements. The system reduced labor from two 8‑hour shifts of 20 employees to a single 10‑hour shift of 7–8 employees, automated the majority of manual operations, and added accumulation and two fluid load lanes to help Garmin meet its five‑year growth objectives.

Garmin