Case Study: RadioShack achieves 100% increase in picking productivity and a 33% smaller DC footprint with Honeywell Intelligrated pick-to-light solution

RadioShack boosts distribution center productivity with Intelligrated pick-to-light system

RadioShack, a national retailer with more than 7,000 locations, consolidated two underutilized Fort Worth distribution facilities into a single optimized DC and set ambitious targets: double picking productivity from 150 to 300 lines per hour, reduce the pick-module footprint by 33%, and increase SKU density to support growing store and e-commerce demand.

Intelligrated delivered a customized zone-routing, pick-and-pass solution using RTS Trak3 pick-to-light hardware, EASYpick software and MDR conveyor, reconfiguring a 68,000 ft² module into a two-level 22,000 ft² system with 79 pick stations. The implementation met or exceeded goals—achieving roughly a 100% increase in pick rate, 99.9% order accuracy, capacity for 500,000 units/day (an extra 3,000 cartons/day), support for ~1,800 more SKUs, ROI in two months, zero downtime during retrofit, and added energy, ergonomic and labor-management benefits.

RadioShack

Jeff Rice

Director of Distribution