Key highlights
<1 day
Average fulfilment from -1.5-2 days
+60%
Throughput uplift - warehouse automation impact
100%
Order-picking accuracy
Summary
One of the largest department stores in the US commissioned around $700 million distribution center spanning around 3 million sq. ft. and required a modern warehouse management platform. Zensar implemented and configured Manhattan Active Warehouse Management, integrated it with warehouse automation (robotics - goods-to-person, pocket sorter, auto boxer, auto bagger) and enterprise systems, and supported QA, testing, go-live readiness, and implementation.
Client overview
A leading North American department store retailer embarked on the development of a next-generation greenfield automated distribution center to transform fulfillment operations and support omni-channel growth. The initiative leveraged advanced warehouse automation technologies to increase throughput, improve inventory accuracy, and establish a scalable foundation for future expansion.
Challenges
Building a scalable, integrated warehouse management foundation for around $700 distribution center
The client needed a throughput of 800,000 units per day during peak season and was therefore commissioning around $700M distribution center spanning around 3 million sq. ft., and needed a modern warehouse management platform. The program required seamless integration between warehouse operations, warehouse automation platforms, and enterprise applications, while also enabling scalable fulfillment capabilities to support multiple brands and future growth.
Solution
Configuring Manhattan Active Warehouse Management and integrating warehouse automation for DC operations
Zensar implemented and configured Manhattan Active Warehouse Management for the new automated distribution center. The solution included customized warehouse processes and integration of WMS with robotics - goods-to-person, pocket sorter, auto boxer, auto bagger and enterprise systems. Zensar also delivered end-to-end quality assurance, testing, go-live readiness, and implementation support.
MAWM implementation
Implemented and configured Manhattan Active Warehouse Management for the new automated distribution center.
Warehouse process customization
Customized warehouse processes to support the new DC operating model.
Automation and enterprise integration
Integrated WMS with upstream and downstream systems
QA and Go-live Support
Delivered end-to-end quality intelligence, testing, go-live readiness, and AI-led implementation support.
To learn more about Zensar’s Manhattan WMS capabilities, click here.
Business outcome
This case study highlights Zensar’s expertise in driving large-scale distribution center transformation through Manhattan Active Warehouse Management. By combining WMS configuration, warehouse process customization, automation and enterprise system integration, quality assurance, testing, and go-live readiness, Zensar helped the client modernize warehouse operations, improve fulfillment speed, enable order consolidation, increase inventory capacity, strengthen store in-stock availability, reduce shipment volumes, and establish a scalable foundation for future multi-brand growth.