CVS is a leading U.S. healthcare and pharmacy retail chain, serving millions of customers through its extensive store network and digital platforms. With a mission to improve health outcomes and streamline access to care, CVS operates multiple large-scale distribution centers to ensure timely delivery of health essentials and retail products. One of its most critical facilities is the 1,000,000+ square foot Lumberton Distribution Center, strategically located to support the densely populated Northeast and New York City metro area.
As consumer demand continued to grow and e-commerce fulfillment requirements became more complex, CVS faced mounting pressure to evolve its distribution capabilities. The company needed to significantly increase throughput to handle higher order volumes, while also reducing reliance on manual labor and improving warehouse safety. At the same time, it aimed to make better use of available space and ensure that any new solution would integrate seamlessly with its existing warehouse management systems (WMS). Despite the expansive footprint of the Lumberton facility, it was limited to a maximum output of 150,000 units per day—placing a hard cap on operational growth and long-term scalability.
To meet rising demand and modernize its operations, CVS became the first retailer to implement a dual robotic automation approach by integrating AutoStore for high-density storage and retrieval with Tompkins Robotics’ tSort for dynamic, high-speed sortation. Together, these technologies created a tightly synchronized system capable of handling high-volume e-commerce fulfillment while optimizing space and reducing manual touchpoints.
This integrated approach provided the flexibility and scalability CVS needed to transform its Lumberton facility. Additional features of the solution included:
Seamless WMS integration for real-time inventory coordination and operational visibility
A network of over 420 autonomous tSort robots operating across 582 pick locations
A modular, flexible design that enables rapid expansion and system reconfiguration
With the deployment of the dual robotic system, Tompkins Robotics’ tSort and AutoStore, CVS transformed its Lumberton Distribution Center into a high-throughput, space-optimized operation. Daily throughput surged from 150,000 units to over 400,000, enabling CVS to process 1.9 million units per week. Plans are in place to scale this further to 3.5 million weekly. Despite the size of the original facility, the robotic infrastructure required only 160,000 square feet to match the output of a traditional 1,000,000 square foot warehouse. This shift delivered significant gains in space utilization and operational efficiency.
The automation upgrade also reduced manual labor, improved safety, and introduced intuitive workflows. Operators can be fully trained in just 15 minutes, further supporting operational agility. These core improvements enabled additional results, including:
Over 99.9% pick accuracy, ensuring near-perfect order fulfillment
40% lower picking costs compared to other CVS distribution centers
Modular, flexible system reconfigurable in minutes with no downtime
Enhanced employee experience, with reduced physical strain and safer working conditions
CVS selected Tompkins Robotics for their proven ability to deliver scalable, flexible sortation systems that integrate seamlessly with existing infrastructure. Tompkins’ modular design and real-time adaptability aligned perfectly with CVS’s commitment to operational excellence and customer satisfaction.
“The combined implementation of Tompkins Robotics' tSort system with AutoStore has transformed the CVS Lumberton Distribution Center, delivering unmatched efficiency, accuracy, and scalability while enhancing employee satisfaction. We’ve been breaking records almost every week with the amount of volume that we’re able to push through that building.”
— Jamie Tatum, Lead Director, Supply Chain Strategy, CVS
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