Roche Diagnostics Indianapolis Distribution Center

Project Overview

Roche Diagnostics, a global leader in healthcare solutions, undertook a major transformation of its North American distribution center located at its headquarters in Indianapolis, Indiana. The primary driver for the project was the aging 15-year-old legacy system, which was experiencing declining reliability. More importantly, the old processes required excessive handling of sensitive medical products, creating inefficiencies and potential quality concerns.

The goal was to implement a modern, integrated distribution system that would streamline operations from storage and picking through to packing and shipping. Roche aimed to improve overall efficiency, enhance quality control, better manage peak demand periods, and create a scalable platform for future business growth. They partnered with Bastian Solutions to design and implement this comprehensive overhaul.

Technical Solution

Warehouse Control System & Administration Cube

The nerve center of the new operation is the "Administration Cube." This area houses the Warehouse Control System (WCS), which provides real-time monitoring and control over the entire conveyor system. It identifies jams, mechanical failures, and generates detailed performance statistics for the operation. This centralized control hub ensures system reliability and provides valuable operational data.

Key Features

The system is designed around a centralized control philosophy with the Administration Cube providing unparalleled visibility and control over the automated processes. The integration of temperature-controlled picking modules (cooler and ambient) is critical for handling Roche's portfolio of diagnostic tools and medical products.

The entire workflow from picking to shipping is connected by a seamless conveyor network, minimizing manual handling and transportation. The inclusion of an automated manifesting process directly linked to the conveyor sortation streamlines the final shipping steps, reducing errors and labor.

Results & Benefits

The transformation delivered significant measurable improvements. The order pack rate increased by 30%, indicating a major boost in packing efficiency. Overtime spending was dramatically reduced by approximately 75%, leading to substantial labor cost savings.

Operational flexibility improved, allowing the facility to manage peak demand periods more effectively. The reduction in unnecessary product handling ("touches") enhanced both process efficiency and product quality. Furthermore, the new system provided detailed operational statistics and positioned Roche Diagnostics for scalable growth, capable of handling increased order lines in the future.

Challenges & Solutions

The core challenge was an outdated, unreliable system that forced inefficient and quality-compromising processes, particularly excessive manual handling of products. The solution was a complete process redesign and system replacement. Bastian Solutions implemented a fully integrated automation solution that re-engineered the workflow from the ground up, connecting storage, picking, packing, and shipping with automated conveyors and controls to minimize manual intervention and create a smooth, reliable flow.

System Integrator

Bastian Solutions served as the system integrator for this comprehensive distribution center transformation. They were responsible for designing and implementing the new system, which encompassed the warehouse control system (Administration Cube), the integrated conveyor network, the pick modules, the packing mezzanine, and the automated manifesting and sortation processes. Their work enabled Roche to achieve its goals of improved efficiency, quality, and cost control.