Customer Profile

When a major Japanese automotive manufacturer needed help managing a 1.25 million sq. ft. warehouse facility adjacent to its car assembly plant, they turned to Capstone Logistics.


The Challenge

  • High turnover and unstable warehouse workforce
  • Daily builds and warehouse backlogs led
  • Frequent production line interruptions
  • Increased costs for warehouse labor
  • The reliance on temp labor exacerbated the problems

The Solution

Capstone engineers began with a detailed operations assessment including time studies and a labor cost analysis:

  • Led setting up of common KPIs with other 3PLs on site
  • Deployed a travel team to stabilize operations and smooth the transition to a long-term solution
  • Data-driven insights for visibility and real-time reporting solution

Once the assessment was reviewed and approved, we put together a full-service solution to meet the customer’s needs.

  • Inbound services: scheduling, receiving, unloading, and put-away
  • Outbound services: picking and packing, and loading
  • Manufacturing support: kitting, light assembly, packing
  • Value-added services: driver support, sanitation and auxiliary services, security and yard management

The Results

Our solutions resulted in:

  • 48% increase in units processed per shift
  • 98% order accuracy and significantly improved order fulfillment speed
  • 36% reduction in headcount
  • 55% year-over-year workforce turnover reduction

The results were so great we were awarded the 2023 Supply Chain Partner of the year from the customer.

Freight Solutions

Unrivaled Transportation and Brokerage

It starts with a commitment to you. Show us your freight management problems, and we’ll show you tangible solutions.

fleet of cargo trucks parked