Warehouse automation is helping First Supply speed up order processing and offer next-morning deliveries
Warehouse robotics have helped US wholesaler First Supply increase picking speeds tenfold and offer next-morning delivery for orders placed as late as 5pm.
The company has deployed Exotec's Skypod robotic system at its distribution centre in West Salem, Wisconsin, as part of efforts to improve warehouse efficiency and support growing customer demand.
First Supply, which supplies heating, ventilation, air conditioning (HVAC), plumbing, building, lighting and industrial products, has introduced the technology to speed up order processing and deliveries to contractors.
The automated system uses vertical storage to accommodate more products within the existing warehouse footprint, reducing the need for employees to travel between picking locations.
According to Exotec, picking speeds have increased tenfold compared with manual operations, while the system now handles more than 14,000 stock keeping units (SKUs).
The technology is also designed to support a fourfold increase in storage capacity without expanding the existing racking footprint.
Exotec said the facility retains capacity for a further 30% hardware expansion, allowing First Supply to increase operations as demand grows.
After more than a year of operation, the system is supporting overnight replenishment across the company's branch network and helping it meet next-day delivery requirements.
Orders requiring next-day fulfilment can account for as much as 20% of the distribution centre's daily volume, placing additional pressure on warehouse operations during busy periods.
Steve Baer, Chief Logistics Officer at First Supply, said the automated system was helping the company manage fluctuations in demand while allowing room for future growth.
“Having a significant percentage of each day’s order volume delivered via the ultra-fast and efficient Skypod system enables First Supply to meet peak season and peak daily demand,” he said.
“The system is productive, efficient, and will enable the facility to grow with minimal disruption over time.”
Beyond faster order processing, the technology has reduced the distances employees need to travel within the warehouse, with picking operations supported by automated product retrieval.
The system was also put to the test during severe flash flooding in southeastern Wisconsin last summer.
First Supply said its automated distribution operation helped the business respond quickly, delivering essential products to hundreds of customers affected by the flooding.
The company believes the investment will support its continued expansion while strengthening its ability to respond to unexpected increases in demand.
Stanislas Normand, Managing Director of Exotec North America, said the project demonstrated how warehouse automation could support both immediate operational requirements and longer-term growth.
“By improving efficiency, supporting growth, and strengthening day-to-day execution, they built a more resilient and scalable operation.”
He said the partnership had helped First Supply improve productivity while developing a distribution operation capable of accommodating future expansion.
The deployment forms part of First Supply's wider modernisation of its distribution network as the fifth-generation family business seeks to maintain service levels and expand its operations.
With demand for faster deliveries continuing, the company is using automation to increase warehouse capacity and maintain next-morning fulfilment without proportionate increases in storage space.