Case Study: Dorman Products achieves 16% travel-waste reduction and 16% pick-rate improvement with Zebra AMRs

Dorman Products Reduces Travel Waste by 16% with Autonomous Mobile Robots (AMRs)

Dorman Products, a long-standing automotive aftermarket parts manufacturer and distributor, needed to speed product movement and reduce wasted contributor travel across its multi-site operations to keep customers satisfied and improve warehouse productivity. With employees walking the equivalent of over 15,000 miles per month, the team sought a flexible automation solution that wouldn’t disrupt operations while freeing contributors to focus on value-added tasks like picking.

Dorman deployed Zebra Freight1500 and CartConnect100 AMRs in a phased roll-out at its 750,000 sq. ft. facility, using simple mapping and drag‑and‑drop workflow software to quickly integrate pallet and cart movements into existing processes. The result: a 16% reduction in travel distance (about 112 miles saved per day), a 16% improvement in pick rate and revenue per labor hour, faster and more accurate dock deliveries, and overall accelerated material movement and order cycle times.

Dorman Products

Ryan Ogden

Operational Excellence (OpEx) Manager