The Stevens Company Case Study

Stevens Company Expands Capacity Without Expanding Footprint

The Stevens Company, one of Canada’s leading distributors of medical supplies, faced a common challenge for long-standing businesses: how to increase throughput and capacity without expanding their facility. After 15 years at the site, growing SKUs and order volumes had outpaced existing processes, making automation the clear path forward.

Stevens needed a reliable, space-efficient solution to scale operations, track sensitive inventory, and maintain free next-day delivery for over 50,000 customers. Partnering with Bastian Solutions, the company implemented advanced technologies seamlessly within the brownfield facility while minimizing disruption to daily operations.

Now, the Brampton site consistently meets targets and scales with ease – reaching 2x the throughput target of the new system on peak days and 10x the legacy system’s throughput during peak season. With 99% of units picked through AutoStore, Stevens has created a flexible, scalable foundation for the future of healthcare distribution.

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Key Technologies

AutoStore System
- 11 R5 Robots
- 18,600 330mm bins
- 10,000 SKUS
- 4 carousel ports
- 230 bin presentations / hour
Bastian Solutions Conveyor
Autonomous Mobile Robots
Exacta™ WCS with lot and serial number tracking

Results

Stevens' Brampton facility now delivers scalable performance and next-day service, achieving results that far exceed their legacy system.

2× Throughput Target on Peak Days – Daily goals consistently met, with the ability to double throughput during demand spikes.
10× Throughput at Peak Season – Compared to legacy processes, the Brampton facility can now process up to ten times the order volume.
25% Increase in Storage Capacity – Expanded inventory within the same footprint to support growing SKUs and product demand.
99% of Units Picked from AutoStore – High accuracy and efficiency from goods-to-person automation.
50,000+ Customers Reached Next Day – Free next-day delivery available to 96% of Canadians.
Maximized Space in Brownfield Facility – Supported growth within the existing footprint, avoiding costly expansion.
Seamless Implementation – Bastian Solutions completed the integration without disrupting ongoing operations.