A large direct marketer and retailer’s distribution center is nearing capacity. To avoid a costly facility expansion, the company will be making customer-direct shipments from a company-owned, manufacturing plant. In addition to supporting the manufacturing operation, the plant’s warehouse will need to ship an average of 3,500 cases per day in 2005, with peaks over 11,000 cases per day. Distribution Design provided analysis and design services for the reengineering to accomplish the company’s objectives. The design includes new processes, layout, conveyor sortation, systems functionality, and the definition of space, people, equipment, and cost requirements for the new operation.