How Borland Doubled Picking Productivity with a Cost-Efficient Distribution Center Retrofit

The Client: Borland International

Borland International experienced rapid order growth driven by expansion and acquisition activity, including integration of Ashton-Tate product lines. As SKU count and direct-order volume increased, the existing distribution center model could not sustain required speed and accuracy performance.

FloStor partnered with Borland to redesign warehouse flow using a retrofit-first strategy that improved throughput and reliability without requiring a full facility rebuild.

The Challenge

• SKU and Order Volume Surge: Rapid growth increased complexity and strained warehouse handling capacity.
• Inefficient Picking Model: Manual cart-based processes and limited pick faces reduced pick-rate performance.
• Congestion and Travel Waste: Legacy racking and wide forklift aisles increased travel distance and process overlap.
• Replenishment/Picking Conflicts: Shared aisles caused operational interference and delayed order flow.
• Cycle-Time and Accuracy Risk: Long order processing windows and limited controls threatened service performance.

The Solution

FloStor implemented a targeted infrastructure retrofit centered on carton flow storage, aisle role separation, and conveyor-enabled order handling. The approach optimized existing physical assets while introducing tighter process control through bar code and system-driven verification.

Instead of pursuing a high-capital rebuild, the project focused on practical layout and flow redesign to deliver rapid performance improvement with lower implementation risk.

Systems Used

• Carton Flow Rack Conversion: Bottom-level pallet rack positions were converted to higher-density pick faces.
• Dedicated Picking/Replenishment Aisles: Activity separation reduced interference and improved movement predictability.
• U-Shaped Warehouse Flow Design: Rack orientation and travel paths were redesigned to reduce picking distance.
• Low-Pressure Accumulation and Sortation Conveyors: Order transfer and destination routing were mechanized for faster processing.
• Barcode-Enabled Closed-Loop Inventory Controls: Scan and validation logic supported higher fulfillment accuracy.

The Power of Integration in Action

FloStor’s integration model aligned storage media, aisle policy, conveyor routing, and inventory controls into a unified operating workflow. This removed friction between picking and replenishment while improving system responsiveness during high order periods.

By combining practical mechanical upgrades with better process logic, Borland achieved large performance gains from a relatively modest capital investment.

The Results

The retrofit delivered substantial improvements in productivity, cycle time, and order quality. Borland transformed a congested, delay-prone operation into a faster, more accurate fulfillment model while preserving flexibility for future change.

Performance gains were achieved with disciplined retrofit execution and without the capital burden of building a new facility.

Why This Worked

This initiative succeeded because Borland and FloStor prioritized system behavior and process discipline over high-cost replacement infrastructure. The retrofit addressed root causes in storage access, movement logic, and control feedback.

• Retrofit-First Strategy: Existing assets were repurposed for faster implementation and stronger ROI.
• Flow-Oriented Layout Engineering: Aisle role clarity and path design reduced congestion and wasted travel.
• Embedded Accuracy Controls: Barcode and verification checkpoints improved consistency at scale.
• Balanced Flexibility and Control: The model supported growth while maintaining adaptable operational execution.

Related Services

• Warehouse Retrofit and Flow Optimization
• Carton Flow and Pick-Face Density Engineering
• Sortation and Conveyor Integration for Order Fulfillment
• Inventory Accuracy Controls and Process Performance Design