Case Study: Distribution Solutions achieves rapid, reliable high-speed distribution center automation with Honeywell Intelligrated

DSI builds shipshape DC for leading department store chain

Distribution Solutions, Inc. (DSI), a third-party logistics provider, was asked to take over container processing at a major department store chain’s Newark import facility where largely manual picking, fulfillment and shipping made operations slow, costly and unable to handle rising volumes. Facing tight timelines and a need for higher throughput and reliability, DSI determined the facility required automation to meet the store chain’s demands and support future growth.

DSI teamed with W&H Systems and Intelligrated to install an automated cross-dock and replenishment system built around a W&H RSU tilted-tray sorter and an Intelligrated high-speed sliding-shoe sorter, plus wave planning, label/scan flows and value-added repack processes. The system was delivered in just over five months, under budget, and produced measurable gains: less than 1% downtime, 99.7% 12‑month on-time delivery, up to 380,000 units processed in a week (double the old facility), a 50% increase in individual labor productivity, cross-dock throughput routinely 10% above plan, and scalable capacity for future expansion.

Distribution Solutions