Case Study: Dick's Sporting Goods achieves 20% productivity increase and uninterrupted operations with Honeywell Intelligrated

Sortation and Conveyor Upgrades Give Dick’s a Competitive Edge

Dick’s Sporting Goods faced the challenge of modernizing sortation and conveyor systems in its expanded 725,000-square-foot Plainfield distribution center to support growing store and online volume without disrupting ongoing operations. Honeywell (Honeywell Intelligrated) was engaged to upgrade the facility’s material handling with solutions including high-speed IntelliSort shoe sorters, IntelliMerge units and InControlWare software tied into Dick’s WMS.

Honeywell implemented a staged tie-in plan and installed dual-sided and single-sided IntelliSort sorters, IntelliMerge merges, and system control/monitoring via InControlWare and ViewCenter, enabling continuous operation throughout the rollout. The upgrades delivered measurable gains: a 20% productivity increase in the breakpack area, a 10% productivity increase in receiving, sustained high throughput (design rates up to about 180 cartons per minute on merges and 100 cpm on the dual-sided sorter), and zero downtime to existing operations.

Dick's Sporting Goods

Bill Palmire

Director of Distribution