From Healing Hands to Seamless Hubs: How LeeSar Scaled Healthcare Supply with Smart Automation

The Client: LeeSar

LeeSar is a healthcare supply alliance that supports multiple Florida hospital systems with centralized sourcing and distribution of critical medical products. As its service footprint expanded across additional campuses, order complexity and fulfillment volume increased sharply.

To sustain growth and service reliability, LeeSar needed a faster, safer, and more scalable distribution model.

The Challenge

• Throughput Bottleneck: Rising line-pick volume stretched daily picking time to roughly 20 hours for one day’s demand.
• Manual Handling Dependency: Legacy tote movement and pick workflows relied heavily on manual labor, limiting speed and consistency.
• Replenishment Interruption: Existing pick zones often required stopping active picking in order to replenish inventory.
• Ergonomic and Safety Pressure: Repetitive manual lifting and transport created strain risk for employees.
• Space and Footprint Constraints: LeeSar needed more processing capacity within a facility layout that required careful space optimization.

The Solution

FloStor designed and integrated a multi-level pick-module architecture that combined vertical transport, conveyorized flow, and replenishment-friendly picking zones. The system shifted work from manual tote movement to controlled product-to-person flow.

The design focused on increasing line-pick throughput, minimizing replenishment disruption, and improving ergonomic conditions while maintaining room for future growth.

Systems Used

• Multi-Level Pick Module: Structured picking zones expanded processing capacity by using vertical space more effectively.
• Three-Story Connex Spiral Conveyor: Compact vertical tote movement reduced travel distance and improved inter-level transfer speed.
• Gravity and Powered Roller Conveyors: Integrated transport paths moved totes smoothly through picking and transfer points.
• Flow Rack Replenishment Design: Back-side replenishment with front-side picking enabled continuous picking without stop-start restock interruptions.
• Ergonomic Product Presentation: Conveyor and rack positioning brought product to pickers at safer, more accessible heights.

The Power of Integration in Action

FloStor’s integration role connected spirals, conveyors, flow racks, and module layout into one coordinated fulfillment workflow. Instead of isolated equipment islands, LeeSar gained a continuous path that synchronized picking and replenishment execution.

This systems-level coordination improved labor productivity while reducing physical handling burden and operational noise in the active work environment.

“Bringing in the conveyors with the addition of flow racking has allowed us to replenish without interrupting the picking process.” – Adam Flood, Process Excellence Manager

The Results

LeeSar transformed a constrained manual operation into a higher-throughput, safer, and more scalable healthcare distribution platform. The upgraded system reduced time-to-complete daily picking demand and improved process stability under ongoing growth.

By integrating vertical movement, continuous replenishment, and ergonomic pick flow, LeeSar gained measurable productivity improvements without sacrificing workforce safety priorities.

Why This Worked

This implementation succeeded because LeeSar and FloStor addressed root workflow constraints instead of adding isolated equipment. The design prioritized throughput, replenishment continuity, and ergonomics as one integrated objective set.

• Bottleneck-First Engineering: The solution targeted line-pick throughput and replenishment conflicts that limited overall performance.
• Vertical Space Utilization: Compact spiral transport increased effective capacity without over-consuming floor area.
• Flow Continuity by Design: Replenishment and picking could run in parallel, stabilizing throughput under load.
• People-Centered Automation: Reduced manual handling and ergonomic improvements supported safer, more sustainable labor performance.

Related Services

• System Integration and Controls Engineering
• Healthcare Distribution Flow Optimization
• Multi-Level Pick Module and Conveyor Design
• Ergonomic Fulfillment Modernization and Lifecycle Support