How Auto Parts Manufacturer Dorman is Using Intralogistics Robots to Save Millions and Slash Labor Needs

GreyOrange x Dorman

For auto parts manufacturers, the ability to process and ship orders swiftly and accurately can make or break a business. At Dorman, a surge in sales brought a daunting challenge: manual forklift operations were struggling to keep pace with demand. With forklift costs soaring to a staggering $5 million annually and errors causing delays and damages, Dorman needed a solution that could enhance efficiency, scale operations and adapt to their growing business needs.

Enter the intelligent orchestration of intralogistics bots. Dorman’s transformation began with the integration of 25 Ranger Intralogistics (RIL) bots powered by GreyMatter intelligent orchestration. This innovative approach aimed to not only streamline operations but also to provide safer, more efficient and cost-effective fulfillment solutions.

The implementation of RIL bots revolutionized Dorman’s warehouse operations across various processes:

  • Dock to Stock: Post pallet assembly, wrapping and inventory entry, Autonomous Mobile Robots (AMRs) seamlessly take charge, transporting pallets to their designated deep storage aisle locations.
  • Replenishment/Shipping: A turret truck efficiently picks pallets from Very Narrow Aisle (VNA) storage and places them on Stationary Transfer Platforms (STPs). This facilitates smooth transportation to various destinations based on material flow requirements.
  • Empty and Recycling Flow: RIL bots efficiently manage the transportation of empty pallets to pallet recycling areas and waste to trash collection points. The flow of materials throughout the warehouse is now streamlined and faster.

The Impact: Millions in projected savings and significant efficiency gains with zero integration requirements

The impact of this transformation was profound, with millions in projected savings and substantial efficiency gains. Key highlights include:

  • Cost Savings: Dorman anticipates saving $4.2 million over three years. This is due to a reduction in manpower, thanks to the optimized operations enabled by RIL bots.
  • Efficiency Gains: Dorman now has RIL bots managing 1,400 pallets per day over two shifts. The deployment has reduced forklift labor requirements by 30% and significantly cut down worker travel time.
  • Workforce Empowerment: By freeing up manual labor previously dedicated to forklift operations, employees were able to transition to more value-added tasks, enhancing overall workforce productivity and job satisfaction.

Moreover, the implementation of RIL bots brought about additional benefits, such as reduced wear and tear on equipment, simplified training for new warehouse employees, and enhanced operational agility through real-time analytics.

In conclusion, Dorman’s decision to adopt intelligent intralogistics bots is a great example of how companies can embrace technology to optimize their warehouse operations. By using automation to overcome the challenges of manual forklift operations, Dorman has not only future-proofed its operations but also positioned itself for sustained growth and competitiveness.

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