FOR IMMEDIATE RELEASE — Bastian Solutions, a Toyota Automated Logistics company, has played a pivotal role in helping Polaris, a global leader in powersports, enhance its parts, garments and accessories fulfillment operations through an innovative facility expansion at its Wilmington, Ohio distribution center. By integrating two key automation solutions together – Packsize’s automated packing systems and AutoStore’s high-density robotic storage solutions – Bastian Solutions has helped Polaris achieve significant gains in efficiency, space utilization and employee satisfaction within its distribution center.
As an experienced integrator, Bastian worked closely with Polaris’ Wilmington distribution center to identify, design and implement an automated solution that addresses the increasing demands of Polaris' growing product lines. This collaboration built on Bastian’s partnership with both Packsize and AutoStore, allowed for a seamless integration of advanced technologies that helped to optimize the entire fulfillment process.
“We are thrilled to be part of this collaboration with Polaris, Packsize and AutoStore. This project is a perfect example of how automation can not only improve operational efficiency but also enhance employee satisfaction,” said Bastian Solutions VP of Global Sales and Applications, Matt Kuper. “We delivered on schedule and under budget, all without disrupting customer operations. This success reaffirms our commitment to delivering innovative, tailored solutions that drive business growth and prioritize employee wellbeing. Every great solution starts with asking the right questions and partnership.”
"Before integrating AutoStore and Packsize, our fulfillment operations were constrained by manual workflows and cycle time inefficiencies,” said Dustin Sockness, Director of PG&A Distribution, Polaris.”By integrating AutoStore’s high-density robotic storage and Packsize’s on-demand custom box-making, we’ve optimized order sequencing and significantly reduced cycle time. This transformation has not only accelerated throughput and improved ergonomics for our team—it’s also reduced turnover and enabled us to scale without expanding our facility.”
After the installation of the automated packaging system and AutoStore’s robotic storage solution, Polaris has seen significant impact at its facility. The facility’s space utilization increased, allowing for better inventory management and greater storage capacity without expanding the physical footprint. The Packsize right-sized packaging system, integrated with AutoStore, delivers the correct carton for each order just in time at each picking port—streamlining the process and reducing manual touches. Bastian Solutions’ Exacta WES optimizes each carton’s size for every order. In addition, with automation handling the more repetitive tasks, employees were able to focus on higher-value work, improving job satisfaction and retention. Faster order fulfillment and enhanced packing accuracy have resulted in quicker deliveries and reduced errors, leading to increased customer satisfaction. Additionally, with more efficient use of space and resources, Polaris’ Wilmington distribution center can scale its operations to meet growing demand while maintaining quality and service.
The successful collaboration between Bastian Solutions, Packsize, AutoStore, and Polaris highlights how automation can drive efficiency, improve employee experiences, and enhance customer service. By leveraging advanced technologies, Polaris optimized its processes, reduced transportation costs, and created a better work environment. This partnership demonstrates the value of customized automation solutions for businesses seeking growth and innovation.
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About Bastian Solutions
Bastian Solutions, a Toyota Automated Logistics company, is a trusted supply chain integration partner committed to providing their clients a competitive advantage by designing and delivering world-class distribution and production solutions. The expertise Bastian Solutions delivers includes exceptional results through a proven process of analytical consulting, engineering and design, simulation, project management, and installation services, while sourcing the best material handling equipment and automation technologies available.
With innovation at the forefront, the company also develops Exacta supply chain software, conveyor and sortation systems, custom automated material-handling equipment, robotics, autonomous vehicles and robotic shuttles, and state-of-the art industrial controls.
Bastian Solutions serves domestic and global markets, covering the United States, Canada, India, Mexico and South America.
About AutoStore
AutoStore™, founded in 1996, is a technology company that develops order-fulfillment solutions to help businesses achieve efficiency gains within the storage and retrieval of goods. The company offers both hardware and software capabilities and the AutoStore technology is interoperable with other third-party solutions.
AutoStore is global, with ~1,550 Systems in 57 countries. All sales are distributed, designed, installed, and serviced by a network of qualified system integrators referred to as "partners".
AutoStore was founded in Nedre Vats, on the west coast of Norway. The company has offices in Norway, the U.S., the UK, Germany, France, Spain, Italy, Austria, South Korea, Japan, Australia, and Singapore, as well as assembly facilities in Poland and Thailand.
About Packsize
Packsize transforms how businesses and their customers experience packaging – from packing to unboxing. Since introducing Right-sized Packaging on Demand in 2002, Packsize has become a recognized supply chain and sustainable packaging industry leader throughout North America and Europe. As a partner and trusted advisor, Packsize creates custom packaging process flows that consider every step – from the warehouse floor to the customer’s hands, accelerating the path to a more sustainable future by delivering Smart Packaging for a Healthy Planet®. Follow Packsize on LinkedIn.
About Polaris
As the global leader in powersports, Polaris Inc. (NYSE: PII) pioneers product breakthroughs and enriching experiences and services that have invited people to discover the joy of being outdoors since our founding in 1954. Polaris’ high-quality product line-up includes the RANGER, RZR, Polaris XPEDITION, and GENERAL side-by-side off-road vehicles; Sportsman all-terrain off-road vehicles; military and commercial off-road vehicles; snowmobiles; Indian Motorcycle mid-size and heavyweight motorcycles; Slingshot moto-roadsters; Aixam quadricycles; Goupil electric vehicles; and pontoon and deck boats, including industry-leading Bennington pontoons. Polaris enhances the riding experience with a robust portfolio of parts, garments, and accessories. Headquartered in Minnesota, Polaris serves nearly 100 countries across the globe. www.polaris.com