Jasco - Oklahoma City Omnichannel Distribution Center Automation

Project Overview

Jasco, a leading provider of consumer electronic accessories and lighting to major North American retailers, faced unprecedented supply chain disruptions, nationwide labor shortages, and evolving omnichannel fulfillment demands. With only 5% automation in its U.S. operations (lagging behind Europe and Southeast Asia), the company’s existing manual processes strained employees—who averaged 16 miles of walking daily to fulfill 20,000+ pallet and parcel orders per day. The global supply chain had also grown longer over two years, requiring a more resilient and efficient distribution infrastructure.

To address these challenges, Jasco partnered with TGW Logistics and Burns & McDonald to develop a highly automated omnichannel distribution center in Oklahoma City. The core objectives were to boost productivity, improve employee ergonomics, alleviate staffing pressures, and support future growth. Launched in April 2022, the facility utilized a design-build methodology and lockstep collaboration to deliver a tailored solution that balanced advanced technology with user-friendliness and operational predictability.

The project aimed to transform Jasco’s distribution capabilities, moving from a manually intensive model to a streamlined, automated workflow that could handle high order volumes while reducing physical strain on employees and mitigating labor scarcity risks.

Technical Solution

Inbound Carton Sortation System

The automated workflow begins with an inbound carton sortation system that efficiently categorizes incoming inventory by type, size, and destination. This system eliminates manual sorting, reducing processing time and errors by automatically directing cartons to the appropriate storage or processing areas. The sortation technology is designed to handle the high-volume inbound flow required to support 20,000+ daily orders, ensuring a smooth start to the fulfillment process.

Key Features

The end-to-end automated workflow—from inbound sortation to outbound shipping—creates a seamless, efficient process that handles 20,000+ daily pallet and parcel orders. This integration eliminates bottlenecks and reduces manual intervention across all core distribution functions.

The ergonomic design of picking stations and semi-automated equipment directly addresses the previous challenge of 16 miles of daily employee walking. By minimizing physical strain, the system improves job satisfaction and retention, critical in a tight labor market.

The user-friendly nature of the retrieval system balances sophistication with simplicity, enabling employees to quickly adapt while providing Jasco with minute-by-minute productivity predictability. This transparency allows for precise operational planning and resource allocation.

Lockstep collaboration between TGW and Burns & McDonald, supported by a design-build methodology, ensured the project was delivered efficiently and aligned with Jasco’s business objectives. This partnership model minimized delays and maximized solution fit.

State-of-the-art packing and sequencing technologies enhance order accuracy and speed, supporting Jasco’s omnichannel retail customers with reliable, timely deliveries.

Results & Benefits

The facility has achieved exponentially improved overall productivity, with automated workflows handling high order volumes more efficiently than manual processes. This performance gain directly supports Jasco’s ability to navigate longer global supply chains and meet growing retail demands.

The ergonomic design and reduced physical strain have helped alleviate staffing challenges by improving employee retention and making the workplace more attractive—critical in a nationwide labor shortage. Employees no longer face 16 miles of daily walking, reducing fatigue and injury risk.

The system’s predictability, with productivity trackable down to the minute, provides Jasco with greater operational control. This visibility enables proactive decision-making and ensures consistent order fulfillment performance.

The automated infrastructure has future-proofed Jasco’s distribution capabilities, positioning the company to support growth for years to come. The solution’s scalability and resilience address the volatility of global supply chains.

By moving from 5% automation to a highly automated model, Jasco has closed the gap with international peers, gaining a competitive advantage in efficiency and reliability while maintaining alignment with North American retail requirements.

Challenges & Solutions

Jasco’s primary challenge was navigating global supply chain disruptions and nationwide labor shortages. The high-automation solution reduced dependency on manual labor, enabling the company to maintain 20,000+ daily order capacity without relying on additional hires.

Excessive employee physical strain—16 miles of daily walking—was a critical issue. The ergonomic automated systems (goods-to-person picking, semi-automated palletizer) minimized walking and repetitive motions, improving workplace conditions and retention.

Longer global supply chains and growing omnichannel demands required a more efficient fulfillment model. The end-to-end automated workflow (sortation, storage, picking, packing) optimized for high-volume, multi-channel orders, ensuring resilience and speed.

The need for efficient, tailored project delivery was addressed through a design-build methodology and collaborative partnership between TGW and Burns & McDonald. This approach ensured the solution met Jasco’s specific needs, with aligned timelines and lean processes.

System Integrator

TGW Logistics served as the primary technology integrator, partnering with Burns & McDonald (construction and delivery specialist) to deliver the turnkey solution. TGW’s expertise in high-volume, omnichannel automation was critical to designing the inbound sortation, shuttle AS/RS, and pick/pack systems that form the core of the facility.

The collaboration between TGW and Burns & McDonald was central to the project’s success, with lockstep coordination between technology integration and construction. This design-build approach allowed for iterative refinement and ensured the solution was delivered on time, within budget, and aligned with Jasco’s operational goals.

TGW’s focus on user-friendly, ergonomic automation ensured the system was both sophisticated and accessible, enabling quick employee adoption and minute-by-minute productivity predictability. The partnership’s trusting relationship and shared commitment to Jasco’s success resulted in a solution that not only addressed immediate challenges but also positioned the company for long-term growth.