To keep pace with diverse product lines and rapid delivery demands, Shimano American Corporation partnered with Fortna and WPSS to expand its distribution centers. By integrating Deluxe Industrial Shelving into new Multilevel Systems, Shimano increased pick locations by 400% in Irvine, CA, and expanded its Ladson, SC facility by 99,000 sq. ft., significantly optimizing its Supply Chain.
The Challenge: Diverse Inventory and Faster Delivery Demands
Shimano American Corporation, a subsidiary of the Japanese giant known for high-quality bicycle components and fishing tackle, faced a transformative business climate. With a product range spanning from small fishing reels to technical athletic clothing, the company needed to adapt to:
- Diverse SKUs: Handling a mix of hard and soft goods of varying sizes.
- Speed Expectations: Customers demanding same-day shipments and improved transit times.
- Capacity Constraints: Existing facilities in Irvine, CA, and Ladson, SC, needed significantly more square footage and improved workflow to handle continued growth.
Shimano turned to supply chain experts Fortna and the engineering specialists at Western Pacific Storage Solutions (WPSS) to overhaul their distribution capabilities.
The WPSS Solution: Deluxe Industrial Shelving Multilevel Systems
WPSS’s Deluxe Industrial Shelving was selected as the core infrastructure for both projects due to its ability to handle heavy-duty, Multilevel Systems applications and integrate seamlessly with other equipment.
Irvine, CA: A 3-Story Efficiency Engine
In California, the team engineered a brand-new 3-level pick module that dramatically increased density within the existing footprint.
- Massive Capacity Boost: The new module increased the number of pick locations from 3,000 to 15,000.
- Hybrid Integration: WPSS successfully integrated new Deluxe Industrial Shelving with existing pallet racking to form a unified structure.
- Custom Engineering: When trash removal became an issue on the upper levels, WPSS engineers designed an innovative trash shoot to accommodate the high workflow volume.
- Code Compliance: The structure was built to meet stringent California building codes and seismic requirements.
Ladson, SC: Expanding the Footprint
In South Carolina, the focus was on large-scale expansion to support employment growth and inventory volume.
- New Construction: A color-matched 2-level pick module was constructed as part of a total expansion that added 99,000 square feet to the facility.
- Growth Ready: The expansion allowed Shimano to increase employment at the facility by 50%, ensuring long-term operational scalability.
Results: Supply Chain Optimization
The collaboration between Shimano, Fortna, and WPSS resulted in two state-of-the-art facilities that are optimized for speed and accuracy.
| Metric | Result | Benefit |
| Pick Locations | Increased from 3,000 to 15,000 (Irvine). | Drastically improved SKU availability and picking speed for diverse products. |
| Expansion | Added 99,000 sq. ft. (Ladson). | Enabled a 50% increase in workforce to handle growing order volumes. |
| Throughput | Faster replenishment via flow racks. | High-volume SKUs are now replenished based on real-time demand, reducing downtime. |
| Partnership | Seamless project execution. | Despite complex permitting and custom engineering needs, both projects were completed successfully through open communication. |
By leveraging Deluxe Industrial Shelving in a custom Multilevel System, Shimano successfully refined its processes, ensuring it remains a leader in both the cycling and fishing industries. Ready to work on your next project? Big or small, WPSS has experts ready to assist! We provide layout guidance, spec sheets, and recommend best-practice clearances to ensure an efficient and space saving design. Contact us today for a quote.