{"id":185,"date":"2025-05-05T18:45:22","date_gmt":"2025-05-05T18:45:22","guid":{"rendered":"https:\/\/api.flostor.com\/backend\/?post_type=case-study&#038;p=185"},"modified":"2026-06-20T00:21:18","modified_gmt":"2026-06-20T00:21:18","slug":"streamlining-success-eas-supplements-distribution-transformation-through-system-integration","status":"publish","type":"case-study","link":"https:\/\/api.flostor.com\/backend\/case-study\/streamlining-success-eas-supplements-distribution-transformation-through-system-integration\/","title":{"rendered":"Streamlining Success: EAS Supplements&#8217; Distribution Transformation Through System Integration"},"content":{"rendered":"\n<h1 class=\"wp-block-heading\">Fueling Peak Performance: How EAS Supplements Built an Order Fulfillment Powerhouse with System Integration<\/h1>\n\n\n\n<h2 class=\"wp-block-heading\">The Client: EAS Supplements<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">EAS develops sports nutrition products for athletes and performance-focused consumers. As demand grew across North American and global channels, order volume outpaced the capabilities of its legacy warehouse infrastructure.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">To keep service levels high and support future growth, EAS needed a faster, more accurate, and more scalable fulfillment system.<\/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>Legacy Infrastructure Constraints:<\/strong> A single forklift and basic conveyor setup could not keep pace with rising order complexity and volume.<\/li>\n\n\n\n<li><strong>Manual-Handling Bottlenecks:<\/strong> High dependence on manual movement slowed throughput and increased risk of picking and routing errors.<\/li>\n\n\n\n<li><strong>Scalability Pressure:<\/strong> Existing operations lacked the capacity and process control required for sustained growth.<\/li>\n\n\n\n<li><strong>Service-Time Expectations:<\/strong> EAS needed to reliably meet same-day shipment requirements for fast-turn orders.<\/li>\n\n\n\n<li><strong>Ergonomic and Labor Efficiency Concerns:<\/strong> Repetitive handling and excessive walking increased strain and reduced productivity.<\/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 designed and integrated a new 141,000 sq ft distribution center architecture that connected guided picking, automated routing, shipment verification, and carrier-specific manifesting into one coordinated flow system. The focus was not just equipment replacement, but end-to-end execution redesign.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The solution combined high-speed conveyance, scan-driven sort logic, and operator-guidance technology to improve throughput, reduce errors, and support same-day fulfillment targets.<\/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>7-Zone Production Picking Lines:<\/strong> Zoned pick workflow supported controlled order progression and efficient multi-box order handling.<\/li>\n\n\n\n<li><strong>Touchscreen and Handheld Scan Guidance:<\/strong> Operator-directed picking with digital instructions improved speed and transactional accuracy.<\/li>\n\n\n\n<li><strong>Integrated Conveyor Network:<\/strong> Gravity, horizontal power, and live roller conveyors moved orders continuously through pick, sort, verify, and manifest stages.<\/li>\n\n\n\n<li><strong>AccuSort Scan and Diverter Routing:<\/strong> Automated barcode-driven sortation directed cartons into carrier-specific lanes using power-pivot diverters.<\/li>\n\n\n\n<li><strong>Verification and Manifest Workstations:<\/strong> Final-check stations with ball transfer tables enabled accurate sealing and carrier handoff preparation.<\/li>\n\n\n\n<li><strong>Ergonomic Process Design:<\/strong> Layout and handling flow were optimized to reduce unnecessary travel and keep most lifts within safer ergonomic ranges.<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"530\" src=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/eas-scheme.jpg\" alt=\"EAS Supplements - Schema\" class=\"wp-image-187\" srcset=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/eas-scheme.jpg 800w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/eas-scheme-300x199.jpg 300w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/eas-scheme-768x509.jpg 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/figure>\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 role unified transport hardware, scan technology, routing logic, and workstation execution into one synchronized fulfillment engine. This removed stop-and-start handoffs and improved order flow predictability from picking through carrier assignment.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Implementation was staged to maintain live shipping continuity, allowing EAS to continue customer fulfillment while the upgraded system came online.<\/p>\n\n\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p class=\"wp-block-paragraph\">&#8220;The installation and operation has gone extremely well.&#8221; &#8211; Shelly Phillips Metz, Vice President of Logistics and Distribution<\/p>\n<\/blockquote>\n\n\n\n<h2 class=\"wp-block-heading\">The Results<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">EAS transformed warehouse operations from a manual throughput limiter into a higher-capacity, higher-accuracy distribution platform. The redesigned process improved shipment reliability and positioned the business for continued growth without sacrificing service speed.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">By combining intelligent routing with operator-guided execution, EAS gained stronger control over order quality and same-day fulfillment performance.<\/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>Throughput Capacity:<\/strong> New operation runs at approximately 1,800 cases per day with additional headroom for growth<\/li>\n\n\n\n<li><strong>Same-Day Fulfillment Capability:<\/strong> Orders received by 2:00 p.m. can be shipped same day, complete and accurate<\/li>\n\n\n\n<li><strong>Order Quality Improvement:<\/strong> Wrong shipments decreased through integrated scanning and verification checkpoints<\/li>\n\n\n\n<li><strong>Labor and Ergonomic Efficiency:<\/strong> Reduced walking distance and safer handling zones improved operator productivity and comfort<\/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 implementation worked because EAS and FloStor treated fulfillment as a system-level redesign rather than a simple equipment upgrade. Picking, routing, verification, and carrier handoff were engineered to operate as one continuous process.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>End-to-End Integration:<\/strong> Physical movement and digital decision logic were synchronized to reduce delays and handoff errors.<\/li>\n\n\n\n<li><strong>Scan-Driven Accuracy Control:<\/strong> Guided picking and automated route assignment improved consistency under higher volume conditions.<\/li>\n\n\n\n<li><strong>Operationally Safe Deployment:<\/strong> Phased installation preserved continuity of live fulfillment during system transition.<\/li>\n\n\n\n<li><strong>People-Centered Performance Design:<\/strong> Ergonomic handling and reduced travel supported sustained output quality.<\/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>System Integration and Controls Engineering<\/li>\n\n\n\n<li>E-commerce and Distribution Flow Modernization<\/li>\n\n\n\n<li>Conveyor Sortation and Verification Architecture<\/li>\n\n\n\n<li>Phased Fulfillment Implementation and Lifecycle Support<\/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>EAS Supplements overcame outdated infrastructure and manual processes by partnering with FloStor to implement an integrated material handling system, resulting in increased efficiency, accuracy, and throughput to meet growing demand.<\/p>\n","protected":false},"featured_media":186,"template":"","meta":{"_acf_changed":false},"categories":[25,30,22],"tags":[31,46,58,52,32,44],"class_list":["post-185","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","category-ecommerce-b2c","category-industry","category-intelligent-motion","tag-conveyors","tag-ergonomics","tag-high-volume-throughput","tag-order-fulfillment","tag-sortation","tag-system-integration"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.7 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Streamlining Success: EAS Supplements&#039; 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