“Growth through customer service” has been the motto at Fastenal, one of the nation’s largest distributors of industrial fasteners, since the company was founded in 1967. Fastenal’s expansion in terms of store locations, number of products and inquiries demanded a new system to fill the orders for 275 stores in the Great Lakes Region and replenish stock at 13 regional distribution centres around the US.

To accommodate that growth, the Winona, Minnesota-based distributor implemented an automated storage and picking system to turn its 530,000 square foot Great Lakes Distribution Centre in Indianapolis from a regional into a master distribution centre.

Requirements & Prerequisites
- Goods-to-person picking system
- 260,000 storage locations in the mini-load
- Ergonomic and efficient environment
- Processing of 30,000 packages per day
- High density storage

Advantages for Fastenal
- “Touches” reduced from 12 to 2 for each item in the distribution centre
- High picking rate per worker
- Fewer stacker cranes due to high velocity
- Cutting down on travel time in the DC
- Reduced injuries through ergonomic workstations
- Improved working moral and less staff fluctuation