Case Study: Scalable, Automated, and Cost-Effective

Transforming East Coast Distribution for Growth

A global sports and outdoor apparel brand faced growing inefficiencies in its U.S. distribution network as direct-to-consumer (DTC) demand surged. Its primary distribution center had exceeded capacity, forcing costly offsite storage, while its East Coast facility struggled with labor shortages, inefficient workflows, and a lack of automation. Without a dedicated East Coast fulfillment strategy, the company relied on long transit times and expedited shipping, driving up operational costs and impacting service levels. Additionally, facility constraints and manual processes slowed order fulfillment, creating challenges in meeting customer expectations.

With continued DTC growth and evolving market demands, the company needed a scalable, cost-effective solution to improve distribution efficiency. It required a future-ready strategy that optimized space, streamlined operations, and reduced reliance on manual labor. The company partnered with Miebach to evaluate its network, identify operational gaps, and design a resilient distribution model capable of supporting long-term growth.

Miebach conducted a comprehensive network assessment to explore expansion, 3PL integration, and a dedicated automated facility. Location analysis identified optimal distribution sites based on labor availability, transit times, and cost efficiency. Miebach’s data-driven approach redesigned fulfillment workflows to enhance productivity, leveraging goods-to-person picking, ASRS, and digital warehouse management to increase throughput while reducing dependency on labor.

To ensure a seamless transition and immediate capacity relief, Miebach structured a phased implementation plan, beginning with a 3PL pilot solution before scaling to a fully automated East Coast facility. This roadmap allowed the company to balance short-term needs with long-term efficiency, ensuring sustainable cost savings and operational resilience.

The company also expanded two-day shipping coverage to 70% of e-commerce customers, lowered storage costs by 15%, and implemented a scalable, resilient distribution model that adapts to future growth. By embracing innovation, the company strengthened its competitive edge and positioned its supply chain for long-term success.