For consolidating five distribution centers into one, a prominent lighting manufacturer had a design for the new facility that closely resembled another existing distribution center. Distribution Design completed a Second Opinion Design, reengineering the proposed operation to fit the higher volumes expected for the new facility. The resulting design for a 700,000 square foot facility used cost justifiable technology to improve the picking and sorting processes. In the new facility, 86% of the cases shipped will be sortable, compared to only 50% of the volume today. The new design also improves productivity and is expected to reduce labor costs by $1.3 million compared to using the existing facility’s picking and sorting technologies.