Case Study: Dick's Sporting Goods achieves 20% breakpack and 10% receiving productivity gains with zero downtime through Honeywell Intelligrated

Sortation and conveyor upgrades give Dick’s a competitive edge

Dick’s Sporting Goods expanded its Plainfield distribution center to 725,000 sq. ft. to support growing store and e‑commerce volume, requiring upgraded conveyor and sortation capabilities without interrupting ongoing operations. The challenge was to install high‑throughput receiving, breakpack and shipping systems while maintaining continuous fulfillment and integrating with corporate WMS.

Intelligrated delivered a phased implementation of high‑speed IntelliSort® shoe sorters, IntelliMerge® merges, conveyors and InControlWare® software with seamless tie‑ins and remote monitoring, allowing Dick’s to keep the old system running until new areas were ready. The upgrade delivered measurable gains — a 20% productivity increase in breakpack, 10% in receiving, designed throughput for sustained high carton rates, and zero downtime during the project.

Dick's Sporting Goods

Bill Palmire

Director of Distribution