Robotic Sortation System Implementation Case Study

This case study details the implementation of a robotic sortation system for a national discount retailer facing challenges with an aging tilt-tray sorter. The existing system had become a bottleneck, threatening outbound throughput and service levels as the retailer's store count and volume increased. The new solution involved a mezzanine-based sortation system that was deployed in parallel with the legacy sorter, ensuring operations continued without interruption. The design incorporates hybrid picking, simulation-led design for scalability, and a flexible staffing strategy to optimize labor efficiency. Post-installation, the system was further refined through collaboration to enhance efficiency and maintain operational integrity. The results included a resilient fulfillment backbone capable of handling increased demands and improved sortation accuracy, ultimately allowing the retailer to trust the new system with tasks previously managed by the outdated sorter.