Case Study: Future-Ready Distribution

Transforming Distribution with Automation

As the company looked to the future, its distribution network lacked the scalability needed to support long-term growth. Managing multiple distribution centers across different regions created inefficiencies, and leadership sought a more streamlined, high-performance network that could consolidate operations without excessive capital investment.

At the same time, rising demand and a projected 17.5% increase in inventory threatened to overwhelm existing facilities. The shift toward e-commerce and direct-to-consumer channels further strained capacity, making it clear that the current infrastructure could not sustain future growth.

• Manual & Inefficient Operations – Over 74% of picking relied on full-pallet handling, increasing labor dependency and slowing fulfillment.
• Suboptimal Layout & Flow – Poor space utilization and fluctuating inbound/outbound flows disrupted efficiency.

While leadership recognized the need for modernization, they lacked a clear roadmap for integrating automation in a way that balanced flexibility, cost-efficiency, and operational agility while creating additional capacity. Miebach was engaged to design a Distribution Center of the Future – one that would drive efficiency, scalability, and long-term success.

The new facility design optimized space, integrating multi-deep shuttle systems and AS/RS for higher storage density and faster throughput. Automation was at the core of the transformation: AGVs replaced forklifts, cutting congestion and improving safety. AMR-supported case picking accelerated fulfillment, while an automated gantry layer-picking system reduced manual handling. 

The project also included scalability planning, evaluating DC consolidation opportunities and a phased automation roadmap for future expansion. A detailed financial model ensured ROI-driven decision-making, and enhancements extended the life of existing facilities while reducing capital expenditures.