30% efficiency gain powers 3PL growth

Challenge

• Evolving customer demands: DSL managed small-batch fulfillment across multiple brands, requiring agility to handle high product variability and fluctuating demand patterns from a diverse client base.

• Labor availability constraints: Frequent attendance issues—with absenteeism reaching up to 30% on some days—created staffing gaps and made it difficult to maintain consistent operational performance.

• Rising labor costs: Increasing wage rates, combined with inconsistent productivity levels, drove up operating costs and created bottlenecks across daily warehouse operations.

• Need for greater operational flexibility: The combination of workforce instability, demand variability, and multi-brand complexity challenged DSL’s ability to scale efficiently while maintaining service levels.

Solution

• Deployed Infios AutoSort Mobile AMRs (Autonomous Mobile Robots) for tabletop sortation.

• Created a centralized automation hub that connected multiple warehouse buildings through shuttle operations, maximizing space utilization and simplifying inventory flow.

• Integrated seamlessly with DSL’s Warehouse Management System (WMS), enabling automated workflows with minimal disruption to ongoing operations.

• Reduced manual handling through goods-to-person automation, improving ergonomics, accelerating order processing, and supporting flexible use cases such as returns processing and retailer-specific ratio packs.