DICK'S Sporting Goods Conklin Distribution Center

Project Overview

DICK'S Sporting Goods, founded in 1948 as a bait and tackle shop in Binghamton, New York, has grown into a leading omnichannel sporting goods retailer with over 700 locations across the United States. The Conklin distribution center represents a strategic homecoming for the company, located just a short distance from where the very first store was established.

This 650,000 square foot facility is the company's fifth distribution center nationally and serves up to 160 stores. The project was driven by the need for speed, flexibility, and flawless execution in an omnichannel retail environment where getting products to stores and customers quickly is paramount.

Bastian Solutions served as the system integrator, designing and implementing a comprehensive material handling system that accommodates the wide variety of sports equipment, apparel, footwear, and accessories offered by the growing retailer.

Technical Solution

Conveyor System Infrastructure

The facility features an extensive 7.5-mile conveyor system designed to handle the diverse product range from DICK'S Sporting Goods. The system accommodates products ranging from 6 inches to 48 inches in length and from 3 pounds to 50 pounds in weight, ensuring efficient transportation throughout the 650,000 square foot facility.

Key Features

The 7.5-mile conveyor system represents a significant engineering achievement, capable of handling the extreme size and weight variations in sporting goods products. The separation of back stock product in receiving has proven to be a major efficiency improvement, freeing up capacity throughout the entire sortation system.

The pallet flow rack system in the shipping area enables FIFO inventory management while maximizing the use of available space. The centralized command center provides complete operational visibility, allowing for faster information distribution to the floor and more efficient operations.

Results & Benefits

The facility has achieved improved overall operational efficiency through optimized material flows and system design. The separation of back stock product from active store orders has freed up significant capacity on the sortation system, improving throughput and reducing bottlenecks.

The pallet flow rack system has maximized square footage utilization in the shipping area, supporting the facility's dense storage requirements. The system provides the speed and flexibility needed for omnichannel fulfillment, ensuring products reach stores and customers quickly.

The centralized command center and Exacta warehouse execution system provide complete operational visibility, enabling proactive problem identification and faster response to operational challenges.

Challenges & Solutions

The primary challenge was handling the extremely wide variety of product sizes and weights typical in sporting goods retail. The solution involved designing a conveyor system capable of handling products ranging from small accessories (6 inches) to large equipment (48 inches) and from lightweight items (3 pounds) to heavy goods (50 pounds).

Another challenge was managing efficient material flows to meet the speed requirements of omnichannel retail. This was addressed through the implementation of a sophisticated receiving sorter with four specialized processing areas and a pallet flow rack system that supports efficient store-specific order fulfillment.

System Integrator

Bastian Solutions provided comprehensive design and integration services, leveraging their expertise in retail distribution technologies. Their partnership with DICK'S Sporting Goods spanned multiple projects, and at the Conklin distribution center, they fully leveraged their resources and capabilities to understand the company's needs and recommend appropriate technologies from the marketplace.