Komar Boosts 3PL Efficiency with Robotics

Overview

Third-party logistics (3PL) providers face unique challenges in today's rapidly evolving supply chain landscape. They must efficiently manage diverse product types, scale operations to meet fluctuating demands, and optimize warehouse space to remain competitive. Komar Distribution Services, a full-service 3PL provider, partnered with Tompkins Robotics to implement an innovative automation solution that transformed their operations and positioned them for continued growth. This case study explores how Tompkins Robotics' tSort system helped Komar Distribution Services overcome their challenges and achieve significant operational improvements.

Solving 3PL Adaptability Challenges

Komar Distribution Services is a full-service 3PL provider that ships a wide variety of products for over 100 brands and 500 retailers. With 2.2 million square feet of warehouse space, Komar specializes in e-commerce, replenishment programs, and bulk shipments, offering scalable and efficient logistic solutions. Komar Distribution Services was experiencing rapid expansion in its B2B replenishment program, which required additional space within their existing traditional pick module. They needed a new sortation system that could accommodate a growing SKU count within a smaller footprint and increase the efficiency of order induction.

Modular Sortation, Scalable Performance

Komar implemented Tompkins Robotics' scalable tSort system, deploying 83 AMRs on a 650-grid tray. This modular and flexible robotic solution enhanced their third-party logistics services by enabling them to process diverse product types for multiple retailers.

Key Benefits and Results

The implementation of the tSort system delivered 6 key benefits to Komar Distribution Services:

• Modular Design for Scalability: The tSort system's modularity allows for easy expansion or reconfiguration, enabling Komar Distribution Services to seamlessly scale operations to meet evolving retailer demand. 
• Space Optimization:
  Requiring 75% less space than traditional systems, the tSort system allowed KDS to process more orders in a smaller footprint, freeing up valuable real estate for other operational needs. 
• Flexible Handling:
  By handling diverse items simultaneously, tSort offered full portability and scalability letting Komar now seamlessly navigate replenishment programs for different retailers each week. 
• Warehouse Safety:
  An overall decrease in mobility requirements led to improved warehouse safety, and mitigated the risk of goods falling from pick modules. 
• Reduced Chargebacks:
  Systemic unit scanning has virtually eliminated sorting errors, leading to a significant reduction in vendor chargebacks. 
• Increased Throughput:
  Komar Distribution Services can now take on any picking or sortation programs needed to process unlimited SKUs without capacity concerns.

Customer Testimonial:

Tyler Harris, President of Komar Distribution Services, stated, "Working with Tompkins Robotic was truly a collaborative experience. We brought our businesses challenges to their team, and they actively worked with us to find the right balance between proven strategies and pushing boundaries in new ways. The Tompkins Team was fantastic in building out a solution for us that was extremely dynamic and would allow us to induct anything we needed to and sort it with a high level of accuracy."

Operations: Streamlined

Tompkins Robotics' tSort system has enabled Komar Distribution Services to streamline operations, optimize warehouse space, improve safety, and unlock their growth potential. This case study highlights Tompkins Robotics' commitment to providing innovative and effective robotic solutions for 3PL providers and other businesses facing complex supply chain challenges.

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Next Steps

Ready to discover how Tompkins Robotics can optimize your logistics and distribution operations? Get in touch with a specialist when you're ready to take the next step!