Case Study: Greenlee achieves 35% labor headcount reduction and significant picking productivity gains with Bastian Solutions

Greenlee - Customer Case Study

Greenlee, a 140‑year‑old maker of electrical tools, was operating a space‑constrained 90,000 sq. ft. distribution center in Rockford, IL with very manual, inefficient processes, high union labor costs and an early 3pm shipping cutoff to meet FedEx pickup times. To reduce labor costs and improve service by relocating closer to FedEx, Greenlee engaged Bastian Solutions to deliver an order‑picking automation solution for their new Southaven, MS facility.

Bastian Solutions implemented a comprehensive automation package — including an Unarco 3‑level pick module with zone pick conveyors, Hytrol ABEZ conveyors, AccuSort scanners, Exacta warehouse control system with SAP interface, scales and RF handhelds — which significantly increased picking productivity. Bastian Solutions’ system enabled Greenlee to cut total labor headcount by 35%, move from three shifts to two, meet productivity goals and position the Southaven DC for growth.

Greenlee