Ingram Solves Space and Labor Challenges with AutoStore

Ingram Content Group produces and distributes printed and digital content to wholesalers as well as online and brick-and-mortar book retailers. With growing demand and limited space, the company needed a solution that would address space and labor challenges, and prepare for future expansion at their facility in LaVergne, Tennessee.

The company implemented AutoStore's automated storage and retrieval system, empowered by KPI Solutions, to support growing demand, make better use of space, and reduce labor dependency. The high-density solution delivered improvements in accuracy, throughput, and operational efficiency. Ingram's retail and library customers now have faster, more efficient access to millions of additional books, and their publishers have a sustainable, integrated inventory solution that improves availability and speeds up time-to-market for their products.

The Challenge: Inventory Growth and Limited Facility Space

Ingram faced various operational challenges that had to be addressed. The company needed to reduce its inventory footprint to create more operational space for future growth opportunities, and was working toward financial goals of reducing operating costs per unit while simultaneously addressing labor challenges.

Particularly during seasonal peaks, labor availability and costs posed significant hurdles to efficient operations.

The Solution: Automated Retrieval and High-Density Storage

After an operational analysis and process evaluation, AutoStore was chosen as the best technology to address Ingram’s needs. The system offered the ability to increase storage density for a diverse assortment of stock keeping units (SKUs). It was ideal for the distributor's varied inventory, allowing for easy rotation of different products in and out as needed.

The AutoStore Grid system features 160 R5 Robots that continuously retrieve and store inventory in over 80,000 Bins. The Robots deliver items to 31 Ports positioned around the facility, where operators process orders and replenish. This configuration enables Ingram to handle high volumes with minimal labor requirements. The system enables simultaneous pick and put-away operations, increasing throughput during both standard and peak periods. AutoStore's Robots operate independently of each other, which ensures continued reliable operations even if one unit requires maintenance.

The high-density storage design allowed Ingram to store more inventory in less space, freeing up valuable floor area for additional operational needs.

Key Benefits: More Space, Higher Accuracy, Optimized Labor

The implementation of AutoStore has delivered significant advantages:

• Efficient use of space: The high-density storage system allows Ingram to store a greater variety of SKUs in a significantly smaller footprint.
• Enhanced labor productivity: Workers achieve higher output rates for both picking and put-away tasks.
• Improved order accuracy: The precision of the AutoStore system has reduced errors and minimized time spent on corrections.
• Reduced labor requirements: The operation now runs with fewer full-time equivalents (FTEs) even as throughput has increased.
• Better working conditions: The ergonomic workstation design and integrated conveyors have improved worker health and safety.

These benefits have combined to create a more efficient, accurate, and scalable operation that positions Ingram Content Group for continued success.

Positioned for Expansion

With the space savings and operational efficiencies gained through AutoStore, Ingram Content Group is now positioned to accommodate future business growth and expand into new opportunities. The scalable nature of the system allows for continued expansion as business needs grow and change.

Project Specifications

• Installation type: Brownfield
• Robots: 160 R5 Robots
• Workstations (Ports): 23 CarouselPorts; 8 ConveyorPorts
• Bins: 80,000+ Bins
• Integrated technology: Conveyor technology
• Implementation partner: KPI Solutions