{"id":204,"date":"2025-05-12T20:49:05","date_gmt":"2025-05-12T20:49:05","guid":{"rendered":"https:\/\/api.flostor.com\/backend\/?post_type=case-study&#038;p=204"},"modified":"2026-06-19T23:59:28","modified_gmt":"2026-06-19T23:59:28","slug":"driving-innovation-in-automotive-distribution","status":"publish","type":"case-study","link":"https:\/\/api.flostor.com\/backend\/case-study\/driving-innovation-in-automotive-distribution\/","title":{"rendered":"Redefining the Road: How CARQUEST and FloStor Are Transforming Automotive Distribution for a New Era"},"content":{"rendered":"\n<h1 class=\"wp-block-heading\">Driving Growth: How CARQUEST Accelerated Distribution Efficiency with a System Integrator<\/h1>\n\n\n\n<h2 class=\"wp-block-heading\">The Client: CARQUEST<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">CARQUEST is a major North American auto parts supplier serving nearly 60 distribution centers and more than 4,000 retail locations. Its value proposition depends on competitive pricing, broad parts availability, and next-day delivery performance across a large service territory.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">As network demand expanded, CARQUEST needed a higher-efficiency distribution model that could improve speed, reduce cost, and support long-term growth.<\/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>Dual-Facility Cost Drag:<\/strong> Operating two separate distribution centers increased overhead and reduced inventory consolidation efficiency.<\/li>\n\n\n\n<li><strong>Extreme SKU Complexity:<\/strong> The central operation needed to support over 200,000 SKUs while maintaining high pick speed and low error rates.<\/li>\n\n\n\n<li><strong>Next-Day Delivery Pressure:<\/strong> Serving a wide geography required fast, highly reliable special-order fulfillment.<\/li>\n\n\n\n<li><strong>Manual and Paper-Based Friction:<\/strong> Legacy workflows constrained throughput and introduced avoidable data-entry and routing errors.<\/li>\n\n\n\n<li><strong>System Coordination Complexity:<\/strong> CARQUEST needed conveyors, storage strategy, software controls, and human workflows to operate as one integrated platform.<\/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 engineered and integrated a consolidated distribution design centered on intelligent conveyorized flow, scan-driven execution, and warehouse management system coordination. The project replaced two legacy facilities with a single purpose-built operation optimized for velocity and control.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The new model aligned inventory placement, order wave strategy, and automated routing logic to improve throughput while creating a stronger foundation for modular expansion.<\/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>Consolidated 145,000 sq ft Distribution Center:<\/strong> Replaced two 180,000 sq ft combined legacy facilities with a denser, better-orchestrated fulfillment layout.<\/li>\n\n\n\n<li><strong>Powered Conveyor and Sortation Backbone:<\/strong> Automated transport and destination routing moved totes\/cartons to correct shipping lanes with reduced manual intervention.<\/li>\n\n\n\n<li><strong>Wave-Based Processing Architecture:<\/strong> Order waves processed up to 20 destinations simultaneously to improve picking and packout flow balance.<\/li>\n\n\n\n<li><strong>Tote License-Plate Tracking:<\/strong> Unique tote identifiers enabled reliable system-level routing and consolidation logic.<\/li>\n\n\n\n<li><strong>WMS and Enterprise Integration:<\/strong> Warehouse controls synchronized with enterprise and POS systems for real-time inventory and order visibility.<\/li>\n\n\n\n<li><strong>RF-Directed Paperless Picking:<\/strong> RF scanners guided pickers, validated picks instantly, and reduced manual transaction errors.<\/li>\n\n\n\n<li><strong>HMI Diagnostics and Flow Control:<\/strong> Operator interfaces provided real-time status monitoring, troubleshooting, and control support across complex automation logic.<\/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 integrator role unified equipment, software, and process design under one execution strategy. By coordinating supplier technologies through a single architecture, CARQUEST gained a more predictable flow model and reduced operational fragmentation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This integrated approach enabled higher output in fewer labor hours while improving inventory velocity and positioning the operation for planned expansion.<\/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;Our productivity is definitely up. We were pulling approximately 300,000 lines out of two locations in a 13 hour shift. We now pull over 400,000 lines out of our new DC in a 10 hour shift.&#8221; &#8211; Jim McMurtrey, VP &amp; General Manager, Auto Parts Wholesale<\/p>\n<\/blockquote>\n\n\n\n<h2 class=\"wp-block-heading\">The Results<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">CARQUEST converted a fragmented dual-site operation into a consolidated, higher-velocity distribution platform with stronger cost efficiency and service responsiveness. The new system improved line output, increased storage density, and reinforced next-day delivery capability.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">With integrated controls and paperless execution, CARQUEST gained the operational discipline needed to manage very large SKU counts at scale.<\/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>Productivity Increase:<\/strong> Line pulls improved from approximately 300,000 lines in 13 hours to over 400,000 lines in 10 hours<\/li>\n\n\n\n<li><strong>Facility Consolidation Efficiency:<\/strong> Two sites totaling 180,000 sq ft were consolidated into one 145,000 sq ft operation<\/li>\n\n\n\n<li><strong>Storage Density Improvement:<\/strong> More inventory was stocked in about 30% less floor area versus prior combined footprint<\/li>\n\n\n\n<li><strong>Designed Throughput Headroom:<\/strong> Conveyor\/sortation system engineered for up to 12,000 totes\/cartons per day<\/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 succeeded because CARQUEST and FloStor treated distribution as an integrated control problem, not a standalone equipment project. Inventory strategy, routing logic, software, and labor execution were designed to reinforce one another.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>End-to-End System Integration:<\/strong> Physical handling and digital controls were synchronized to reduce handoff errors and flow interruptions.<\/li>\n\n\n\n<li><strong>High-SKU Execution Discipline:<\/strong> RF-guided paperless workflows improved pick precision and transaction integrity at scale.<\/li>\n\n\n\n<li><strong>Consolidation with Performance Gain:<\/strong> Facility consolidation lowered cost while improving service and output metrics.<\/li>\n\n\n\n<li><strong>Scalable Architecture:<\/strong> Modular components and planned expansion zones created a long-term growth path without full redesign.<\/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>Distribution Center Consolidation Planning<\/li>\n\n\n\n<li>Conveyor and Sortation Workflow Design<\/li>\n\n\n\n<li>RF\/WMS Fulfillment Modernization and Scalability Planning<\/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>By partnering with FloStor, CARQUEST transformed its distribution network-achieving faster delivery, greater efficiency, and unmatched reliability. This bold move redefined their supply chain, setting a new benchmark for innovation and excellence in the automotive industry.<\/p>\n","protected":false},"featured_media":205,"template":"","meta":{"_acf_changed":false},"categories":[30,22,29],"tags":[31,58,52,32,44,39],"class_list":["post-204","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","category-industry","category-intelligent-motion","category-warehouse-distribution","tag-conveyors","tag-high-volume-throughput","tag-order-fulfillment","tag-sortation","tag-system-integration","tag-wms"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.7 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Redefining the Road: How CARQUEST and FloStor Are Transforming Automotive Distribution for a New Era - Flostor<\/title>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Redefining the Road: How CARQUEST and FloStor Are Transforming Automotive Distribution for a New Era - Flostor\" \/>\n<meta property=\"og:description\" content=\"By partnering with FloStor, CARQUEST transformed its distribution network-achieving faster delivery, greater efficiency, and unmatched reliability. 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