Faced with facility constraints, labor shortages, and explosive SKU growth, a major retailer partnered with Trew to automate a 430,000 sq ft omni-channel fulfillment center. The solution integrated SmartMoves WX® WES, ASRS, and over 3.5 miles of conveyance to support both retail and e-commerce. The result? 5-8x throughput gains, 80% automation of manual tasks, and a scalable, future-ready operation.
The Challenge
The pre-built facility had multiple sides, low ceilings, limited power, and flooring issues that made automation difficult. Labor shortages and rising costs added pressure, while unmanaged SKU growth and limited inventory visibility complicated operations. The customer needed to handle diverse inbound goods, manage returns, and find an efficient storage solution for varied order types.
The Solution
Despite significant facility constraints, the customer maintained manual operations and met DC commitments while Trew managed floor remediation, poured a new slab, and operated on generators during switch gear delays. Advanced technologies including WES, put-to-light, and cross-docking were integrated to scale operations and reduce labor costs, while the solution was customized for shared inventory and omnichannel fulfillment.
The Result
Trew transformed operations by optimizing storage, order processing, and shipping through advanced technologies like WES, put-to-light, and cross-docking. The system automated more than 80% of manual processes, boosting throughput by 5-8x, and delivered long-term benefits including scalability, efficiency, cost savings, and future growth.
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