{"id":15,"date":"2025-03-12T18:33:28","date_gmt":"2025-03-12T18:33:28","guid":{"rendered":"http:\/\/apiflostor.wwwmi3-sr4.supercp.com\/backend\/?post_type=case-study&#038;p=15"},"modified":"2026-06-20T01:18:01","modified_gmt":"2026-06-20T01:18:01","slug":"case-study-borland-internationals-distribution-center-retrofit","status":"publish","type":"case-study","link":"https:\/\/api.flostor.com\/backend\/case-study\/case-study-borland-internationals-distribution-center-retrofit\/","title":{"rendered":"Borland International&#8217;s Distribution Center Retrofit"},"content":{"rendered":"\n<h1 class=\"wp-block-heading\">How Borland Doubled Picking Productivity with a Cost-Efficient Distribution Center Retrofit<\/h1>\n\n\n\n<h2 class=\"wp-block-heading\">The Client: Borland International<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Borland International experienced rapid order growth driven by expansion and acquisition activity, including integration of Ashton-Tate product lines. As SKU count and direct-order volume increased, the existing distribution center model could not sustain required speed and accuracy performance.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">FloStor partnered with Borland to redesign warehouse flow using a retrofit-first strategy that improved throughput and reliability without requiring a full facility rebuild.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Challenge<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>SKU and Order Volume Surge:<\/strong> Rapid growth increased complexity and strained warehouse handling capacity.<\/li>\n\n\n\n<li><strong>Inefficient Picking Model:<\/strong> Manual cart-based processes and limited pick faces reduced pick-rate performance.<\/li>\n\n\n\n<li><strong>Congestion and Travel Waste:<\/strong> Legacy racking and wide forklift aisles increased travel distance and process overlap.<\/li>\n\n\n\n<li><strong>Replenishment\/Picking Conflicts:<\/strong> Shared aisles caused operational interference and delayed order flow.<\/li>\n\n\n\n<li><strong>Cycle-Time and Accuracy Risk:<\/strong> Long order processing windows and limited controls threatened service performance.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">The Solution<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">FloStor implemented a targeted infrastructure retrofit centered on carton flow storage, aisle role separation, and conveyor-enabled order handling. The approach optimized existing physical assets while introducing tighter process control through bar code and system-driven verification.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Instead of pursuing a high-capital rebuild, the project focused on practical layout and flow redesign to deliver rapid performance improvement with lower implementation risk.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Systems Used<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Carton Flow Rack Conversion:<\/strong> Bottom-level pallet rack positions were converted to higher-density pick faces.<\/li>\n\n\n\n<li><strong>Dedicated Picking\/Replenishment Aisles:<\/strong> Activity separation reduced interference and improved movement predictability.<\/li>\n\n\n\n<li><strong>U-Shaped Warehouse Flow Design:<\/strong> Rack orientation and travel paths were redesigned to reduce picking distance.<\/li>\n\n\n\n<li><strong>Low-Pressure Accumulation and Sortation Conveyors:<\/strong> Order transfer and destination routing were mechanized for faster processing.<\/li>\n\n\n\n<li><strong>Barcode-Enabled Closed-Loop Inventory Controls:<\/strong> Scan and validation logic supported higher fulfillment accuracy.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">The Power of Integration in Action<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">FloStor&#8217;s integration model aligned storage media, aisle policy, conveyor routing, and inventory controls into a unified operating workflow. This removed friction between picking and replenishment while improving system responsiveness during high order periods.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">By combining practical mechanical upgrades with better process logic, Borland achieved large performance gains from a relatively modest capital investment.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Results<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The retrofit delivered substantial improvements in productivity, cycle time, and order quality. Borland transformed a congested, delay-prone operation into a faster, more accurate fulfillment model while preserving flexibility for future change.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Performance gains were achieved with disciplined retrofit execution and without the capital burden of building a new facility.<\/p>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-f56f613f wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column caseStudyResultsBox is-layout-flow wp-block-column-is-layout-flow\">\n<h3 class=\"wp-block-heading\">Key Performance Gains<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Picking Productivity Increase:<\/strong> Pick rate improved from approximately 67 to 156 picks per hour<\/li>\n\n\n\n<li><strong>Order Cycle-Time Reduction:<\/strong> Processing time reduced from roughly 2-3 days to about 24 hours<\/li>\n\n\n\n<li><strong>Order Accuracy Improvement:<\/strong> Two-step verification supported materially higher fulfillment precision<\/li>\n\n\n\n<li><strong>Capital Efficiency:<\/strong> Major operational gains delivered with a project budget under $150,000<\/li>\n<\/ul>\n<\/div>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Why This Worked<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">This initiative succeeded because Borland and FloStor prioritized system behavior and process discipline over high-cost replacement infrastructure. The retrofit addressed root causes in storage access, movement logic, and control feedback.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Retrofit-First Strategy:<\/strong> Existing assets were repurposed for faster implementation and stronger ROI.<\/li>\n\n\n\n<li><strong>Flow-Oriented Layout Engineering:<\/strong> Aisle role clarity and path design reduced congestion and wasted travel.<\/li>\n\n\n\n<li><strong>Embedded Accuracy Controls:<\/strong> Barcode and verification checkpoints improved consistency at scale.<\/li>\n\n\n\n<li><strong>Balanced Flexibility and Control:<\/strong> The model supported growth while maintaining adaptable operational execution.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Related Services<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Warehouse Retrofit and Flow Optimization<\/li>\n\n\n\n<li>Carton Flow and Pick-Face Density Engineering<\/li>\n\n\n\n<li>Sortation and Conveyor Integration for Order Fulfillment<\/li>\n\n\n\n<li>Inventory Accuracy Controls and Process Performance Design<\/li>\n<\/ul>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n","protected":false},"excerpt":{"rendered":"<p>Borland International, Inc., founded in 1983 by Philippe Kahn, is a pioneering software company that made its mark by developing innovative tools for programmers and corporate software users.<\/p>\n","protected":false},"featured_media":23,"template":"","meta":{"_acf_changed":false},"categories":[30,22,29],"tags":[31,52,50,44,45],"class_list":["post-15","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","category-industry","category-intelligent-motion","category-warehouse-distribution","tag-conveyors","tag-order-fulfillment","tag-scalability","tag-system-integration","tag-warehouse-design"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.7 - 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