Case Study
Codale, Sonepar
How AutoStore Powers Fast, Same-Day Pickup at Scale
Country
USA
Industry
Industrials
Partner
Kardex Holding AG
AI Translated | Original AutoStore Content
Learn how AutoStore supports fast, same-day pickup in a space-constrained market.
Codale Electric Supply, a regional subsidiary of global B2B electrical distributor Sonepar USA, has transformed fulfillment operations in Las Vegas with an AutoStore system designed for speed, density, and long-term scalability, empowered by Kardex.
Operating in a dense urban market with exceptionally high walk-in demand from electrical contractors, Codale needed a fulfillment solution that could consolidate multiple operations, respond faster than ever, and scale with future growth within a limited physical footprint. AutoStore provided the foundation for a high-performance central distribution center that now serves as a blueprint for future Sonepar facilities across the United States.
As part of the wider Sonepar network, Codale builds on a proven automation strategy. Sonepar has deployed more than 12 AutoStore systems globally, using a standardized approach to support high-density storage, fast fulfillment, and scalable operations across its distribution network.
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Following Codale’s acquisition of NEDCO in 2023, three Sonepar regional brands Codale, QED, and NEDCO were operating independently across multiple Las Vegas locations. Each site relied on manual workflows, separate ERP environments, and localized inventory visibility.
As order volumes increased, this fragmentation limited throughput and accuracy, particularly for same-day Will Call orders that are essential to electrical contractors in the Las Vegas market.
Codale needed a unified, automated fulfillment model that could support both present requirements and future growth.
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Codale selected AutoStore as the core of its new Las Vegas Central Distribution Center, with the system empowered by Kardex software and integration expertise.
AutoStore provides a Goods-to-Person model that stores Bins (totes) in a compact Grid and uses Robots to retrieve inventory and deliver it directly to Ports (Workstations). This eliminates travel time, manual searching, and forklift movement, which is critical in a space-constrained urban facility.
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The AutoStore system supports two distinct workflows within the same Grid:
Orders are dynamically prioritized so both workflows operate simultaneously without congestion.
AutoStore compresses approximately 9,700 SKUs into a Grid footprint of just 5,500 ft² (511 m²), reducing floor space requirements by roughly 80% compared to traditional warehousing. This density allowed Codale to locate its Central Distribution Center, (CDC) close to the Las Vegas Strip, improving convenience for walk-in customers.
AutoStore Robots travel on top of the Grid, retrieving Bins and delivering them to ergonomic Ports operated by warehouse employees. Every SKU is immediately accessible, enabling consistent performance even during peak demand periods.
Operators are guided through each task with visual instructions at the Ports. Reduced scanning steps and clearer guidance have driven a 90% reduction in barcode scan errors, significantly improving accuracy.
These improvements have strengthened Codale’s ability to deliver fast, reliable service to contractors.
AutoStore Ports reduce unnecessary motion and physical strain, improving ergonomics and job satisfaction. Integrated cartonization logic supports right-sized packaging, reducing corrugated waste and freight emissions in line with Sonepar’s ESG targets.
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AutoStore’s modular architecture allows Robots and Ports to be added without disrupting live operations. This gives Codale confidence that the system will grow alongside its business.
The Las Vegas CDC now serves as a proven model for future Sonepar distribution centers, demonstrating how high-density automation can support speed, reliability, and long-term flexibility.
“This is technology that’s going to change the way logistics is run, and it’s something I would recommend for any company.”
Codale operations representative
“It has improved customer experience immensely.”
“We’ve seen our response times nearly cut in half.”
“One of the things that really set the AutoStore system apart from everything else we were looking at was scalability.”
“This is something I would recommend for any company. It's something that's going to move all logistics into the future.”
AutoStore can fit any warehouse or fulfillment center. Make yours the next.
