Case Study
Guided strategic decision to modernize an existing facility
Operated successfully in 25% of the original building footprint
Improved productivity and throughput while maintaining service levels
Ensured business continuity through a 2.5-year construction and transition
Resolved multimillion-dollar infrastructure challenges without significant project delays
Built long-term trust through deep, hands-on collaboration with client teams
Footwear and apparel retailer
Multi-banner network with national distribution
$1B+ in annual revenue
Following the acquisition of a West Coast–based retail banner, a leading North American footwear and apparel retailer set out to modernize the newly acquired fulfillment center. The legacy facility relied heavily on manual operations and occupied 431,000 square feet of space, an unsustainable footprint given the company’s modernization goals and projected growth.
Summit Advisory Team was engaged to support a ~$75M modernization plan, manage implementation across multiple stakeholder groups, and ensure operational continuity as automation was introduced. Summit’s role went beyond traditional project management; it acted as the bridge between IT, supply chain, automation partners, and executive leadership to align strategy, design, and execution.
The objective was to transition the legacy fulfillment operation into a multi-banner automated facility without disrupting day-to-day business or compromising service levels. Summit was tasked with guiding the project from design through go-live, identifying potential risks early, and driving resolution across infrastructure, system integration, and operational design.
Summit deployed a two-person leadership team with extensive experience in logistics, engineering, and program management to manage both the strategic and operational dimensions of the project. Serving as the central hub, the program manager aligned people, processes, and priorities across three organizational tiers—a global parent, a U.S. brand, and the acquired West Coast banner—while coordinating automation, IT/architecture, operations, finance, and local project management.
Working alongside the program manager, Summit’s operations and engineering lead managed the day-to-day performance of the existing facility during construction, designing and executing the interim plan to operate in 100,000 square feet, roughly 25% of the building. Together, the two leaders bridged strategy and execution—keeping the modernization effort on track, resolving issues before they became roadblocks, and maintaining clear communication between executive stakeholders and on-the-ground teams.
Over the course of 2.5 years, they worked shoulder to shoulder with the client’s staff, becoming fully integrated members of the operations team. This hands-on partnership built deep trust and ensured that Summit’s recommendations were not only strategic but grounded in the realities of daily execution.
Summit began by assessing multiple options for modernization, comparing the cost, risk, and long-term scalability of new construction versus retrofitting the acquired West Coast facility. Their data-backed recommendation to modernize the existing site set the stage for the full project, aligning with the retailer’s financial and operational objectives.
Summit played a pivotal role in shaping the automation and facility design. By leveraging deep technical experience with automation and systems integration, Summit’s team worked in partnership with the automation provider to optimize layout and process decisions aimed at improving functionality and scalability.
Acting as both a strategic advisor and on-site engineer, the Summit consultant worked closely with the automation partner and internal IT and operations teams to ensure the design supported future multi-banner growth and integrated seamlessly across systems.
To maintain operations during construction, Summit developed a detailed plan to consolidate 431,000 square feet of activity into just 100,000 square feet. The restructured workflow not only preserved service continuity but improved productivity and product flow.
Process changes, enabled by small-parcel shipping, shifted stores from one to two bulk replenishments per week to daily shipments, freeing floor space and accelerating time-to-store.
Early in the project, Summit helped solve significant infrastructure constraints, including seismic-grade slab reinforcement needs and insufficient electrical capacity. Working with engineers and the local utility company, the team managed extensive slab reinforcement and a large temporary generator while awaiting permanent upgrades.
In parallel, Summit coordinated integration between the retailer’s order management and warehouse management systems and the new automation platform to ensure seamless communication across systems.
Summit led the creation and execution of test scripts, standard operating procedures (SOPs), and training materials to support a smooth transition. These resources established clear processes for both automated and manual workflows, providing the foundation for ongoing operational excellence.
Throughout the engagement, Summit’s proactive approach and deep industry expertise enabled early detection and resolution of potential issues, from seismic reinforcement requirements to power constraints and supply chain delays. By facilitating transparent communication and cross-functional alignment, the team fostered a trusted partnership that empowered faster, more informed decision-making.
Despite significant infrastructure challenges and external constraints, the retailer successfully transformed its West Coast fulfillment operation into a modern, efficient, and scalable facility.
By embedding deeply with the client’s team, Summit combined strategic insight with decades of real-world experience to ensure every decision—from design to daily execution—was both strategically sound and operationally practical. The retailer now operates a future-ready fulfillment network built on scalable automation, efficient workflows, and a foundation of trust that extends beyond the project itself.