PUMA Indianapolis Pandemic-Resilient Distribution Center

Project Overview

The PUMA Indianapolis distribution center project was launched against the backdrop of a global crisis. With the onset of the COVID-19 pandemic, the retail industry experienced an explosive and unexpected acceleration in e-commerce activity, transforming everyday demand into sustained peak-season volumes. PUMA needed a solution that could not only support its existing growth plans but also withstand the immense pressure of this new reality.

This facility was conceived as a strategic hub for PUMA's North America e-commerce retail distribution. Its timely opening was critical, as the pandemic-triggered surge in business created an urgent need for additional fulfillment capacity. The goal was to design and implement an automated distribution center that could open on schedule despite worldwide disruptions, immediately handle accelerated demand, and provide a scalable platform for PUMA's ambitious plan to double its business over the next five years.

Bastian Solutions led a collaborative effort with PUMA, automation provider AutoStore, and third-party logistics operator NFI/Cal Cartage to bring this vital project to life.

Technical Solution

(Note: Specific technical modules are not detailed in this description. Based on the context, partnership with AutoStore, and reference to a related case study, the system likely mirrors the advanced goods-to-person automation described in the "PUMA and Bastian Solutions: A Retail Fulfillment Game Changer" case study from September 2021.)

Key Features

The most significant feature of this project was its successful execution against all odds—opening on time and on budget in June 2020, at the height of the pandemic's operational and logistical chaos. This achievement was a direct result of exceptional collaboration and adaptive project management among all partners.

The facility was strategically designed for long-term growth. Its current 670,000-square-foot footprint includes plans for a 400,000-square-foot expansion, providing the physical scalability to support PUMA's goal of doubling its business. The automation within was implemented to handle the intense, sustained demand that characterized pandemic-era e-commerce, essentially operating at "Black Friday" levels daily.

Results & Benefits

The on-schedule launch in mid-2020 provided PUMA with a critical "beacon of hope" and the operational capacity to capture and manage the massive surge in online sales during the pandemic. It successfully serviced the accelerated business that emerged, preventing a potential fulfillment breakdown.

Beyond immediate crisis management, the DC positioned PUMA perfectly for its strategic five-year growth plan. It demonstrated remarkable resilience, operating safely throughout the installation with no reported COVID-19 incidents on site, thanks to strict safety protocols managed by Bastian and NFI/Cal Cartage. The project delivered not just a building, but a tangible symbol of forward momentum and future capability for the company.

Challenges & Solutions

The overarching challenge was executing a major capital project during the global COVID-19 pandemic, which introduced severe supply chain delays, travel restrictions, and stringent health safety requirements. The solution was a unified, adaptable partnership. Bastian Solutions coordinated closely with NFI/Cal Cartage's on-site team to implement strict safety measures (like enforced distancing) while maintaining relentless focus on project milestones, ensuring the system was delivered as promised.

A parallel challenge was the unforeseen explosion in e-commerce demand, which quickly overwhelmed existing infrastructure. The timely completion of the Indianapolis DC was itself the solution. By opening precisely when needed, it provided the necessary high-volume, automated fulfillment capacity to absorb the "every day a Black Friday" demand levels, turning a potential crisis into a strategic advantage.

System Integrator

Bastian Solutions was the lead system integrator for this high-stakes project. Their role encompassed system design, integration of the AutoStore technology, project management, and on-site coordination during the pandemic. They are credited with outstanding performance in navigating pandemic-related challenges, ensuring the safety of personnel, and delivering the complete automation system on time and on budget. This successful delivery under extreme conditions solidified the partnership and provided PUMA with the crucial capabilities needed during a pivotal moment for the retail industry.