Key highlights
65%
Sales growth supported
+34%
Peak-day fulfillment rate increase
3X
Higher UPH for GTP picks
+25% productivity
Improved labor efficiency through increased warehouse automation
+50% storage capacity
Expanded storage utilization using goods-to-person automation
Summary
Zensar partnered with a leading retailer to modernize a brownfield warehouse environment through Manhattan WMOS 2010-led automation. As the implementation partner, Zensar configured, extended, integrated, and tested multiple automation systems across picking, packing, sortation, conveyors, MHE, and enterprise interfaces. The transformation improved fulfillment throughput, enhanced peak-day readiness, and created a scalable automation foundation for future distribution centers.
Client overview
Brownfield warehouse automation modernization with Manhattan WMOS 2010
A leading retailer operating a large distribution network needed to modernize its existing warehouse operations to support rising fulfillment volumes and peak-day demand. The warehouse environment was built on Manhattan WMOS 2010 and required tighter orchestration with automation systems to improve throughput, reduce manual effort, and enhance operational efficiency. Zensar was selected as the implementation partner to configure, extend, integrate, test, and stabilize a highly automated brownfield warehouse ecosystem while maintaining continuity across existing operations.
Challenges
Modernizing an existing warehouse ecosystem to support next-generation fulfillment operations
The client needed to modernize a brownfield warehouse environment built on Manhattan WMOS 2010 while supporting growing fulfillment volumes and peak-day demand. Existing operations required higher throughput, improved storage utilization, stronger automation orchestration, and reduced reliance on manual processes. The client also needed to integrate multiple automation technologies with the existing warehouse platform without disrupting business continuity. Zensar’s role was to help transition the warehouse from a legacy operating model to a more automated, scalable, and peak-ready fulfillment ecosystem.
Solution
Delivering Manhattan WMOS 2010-led warehouse automation across fulfillment workflows
Zensar implemented a brownfield warehouse automation transformation powered by Manhattan WMOS 2010. The engagement included configuration, extension, integration, and testing of multiple automation systems across goods-to-person robotics, automated packing, sortation, conveyors, MHE, and enterprise interfaces. Zensar also migrated supporting legacy applications to cloud infrastructure and delivered end-to-end integration, automation sequencing, QA validation, and go-live readiness to ensure stable, peak-ready warehouse operations.
Manhattan WMOS 2010 automation orchestration
Leveraged Manhattan WMOS 2010 as the core warehouse execution and orchestration layer for brownfield automation modernization.
Goods-to-person automation
Integrated goods-to-person robotics to reduce travel time, improve picking productivity, and increase fulfillment throughput.
Sortation, packing and conveyor integration
Integrated automated packing, sortation systems, conveyors, and MHE to streamline fulfillment workflows and reduce manual intervention.
Cloud migration and go-live readiness
Migrated supporting legacy applications to cloud infrastructure and delivered QA validation, automation sequencing, and peak-readiness support.
To learn more about Zensar’s Manhattan WMS capabilities, click here.
Business outcome
Zensar helped the client modernize its warehouse operations into a highly automated fulfillment environment powered by Manhattan WMOS 2010. Through automation integration, cloud migration, QA validation, and go-live readiness support, Zensar improved warehouse throughput, enhanced peak-day fulfillment performance, strengthened automation orchestration, and reduced manual dependency across picking, sorting, packing, and material handling processes. The engagement enabled a seamless brownfield transformation without disrupting the existing warehouse ecosystem, while establishing a scalable foundation for future distribution center modernization and next-generation fulfillment initiatives.