Home » Resources » Warehouse Consolidation Case Study

Consolidation a Picking & Shipping Operation from 10 Buildings to a Single Location

Written by Tom Compton


A parts distributor contacted ISS looking to consolidate their picking and shipping operation from 10 buildings to one efficient location.


ISS performed a full-scale inventory analysis, measuring each of the ten buildings and determining the sizes of the products in each facility. From there, the team at ISS met with the customer to understand their operation and generated multiple AutoCad layouts to find the most efficient option for their new distribution center. A 2 level pick module was the ideal solution.

Receiving Area

A truck full of inventory can pull up to multiple dock doors to be unloaded. From there, the inventory will be put away on the main level or sent to the second level via conveyor, a pallet drop area, or the VRC (Vertical Reciprocating Conveyor).

Heavy Conveyor

To transport items, a heavy conveyor runs the length of the second level to move inventory to the mezzanine level and orders down to the main level.

Vertical Reciprocating Conveyor

A vertical reciprocating conveyor (VRC) transports bulkier items to the second level. 


A variety of different size shelving, racking, and drawers store the multitude sized inventory, ranging from the size of a nut and bolt up to 8’ deep boxes.

Shipping Area

Once the order is picked, inventory congregates in the shipping area and are packaged and staged to be ready to load onto trucks.

Staging Bins

A multitude size bins to have orders ready to be loaded on delivery trucks


The customer couldn’t have been more pleased with how their new DC turned out and appreciated the full turnkey solution ISS was able to provide including inventory analysis, design, materials, and installation.

Looking for customized solutions for your next warehouse consolidation project? Call us today for a consultation!

Contact ISS Material Handling for a Free Consultation 

Do you think ISS Material Handling could benefit your operations? Contact us and we can merge our experience and expertise to come up with a solution together. Tell us about your potential project and submit the form below or give us a call at 833-754-2164.