How MSC Used AutoStore Warehouse Automation to Boost Throughput and Employee Satisfaction

Brent Davis & Sheila Dooley | 21 May 2025

MSC Industrial Supply Co. knew it was time to update how work got done inside its customer fulfillment centers. With growing demand and a vast product catalog, they needed a way to handle more volume while improving the day-to-day experience for employees on the floor. That meant reducing physically demanding tasks, increasing flexibility, and building a more efficient system for order fulfillment.

As a leading distributor of metalworking and MRO (maintenance, repair and operations) products, MSC serves manufacturers and industrial customers across North America. Their operation includes over 7,000 associates and millions of SKUs flowing through two major fulfillment centers in Harrisburg, Pennsylvania, and Elkhart, Indiana.

MSC partnered with Bastian Solutions to implement an AutoStore goods-to-person system to keep pace and create a more sustainable workflow. The result was a more productive operation that supports both the needs of employees and the expectations of customers.

What is AutoStore and Why MSC Chose It

AutoStore is a compact, high-density storage and retrieval system that uses robots to move bins containing inventory to workstations where operators pick items for orders. Instead of walking aisles or lifting heavy totes, employees stay at ergonomic workstations while inventory comes to them. For MSC, this shift marked a major change in how work was organized inside the facility.

The decision to implement AutoStore came after evaluating how to handle more throughput within the existing footprint of their facilities. “We decided to automate two distribution centers... specifically for throughput, to gain efficiencies within the same footprint that we currently have,” said Mindy Wright, Customer Fulfillment Director at MSC. The need for a smarter system was clear, with nearly 2.4 million SKUs moving through these centers.

Before material handling automation, the process was entirely manual. “It was very taxing on our associates,” said Darin Russell, Senior Director of Supply Chain Engineering Services. “Bastian was able to come into our facility, evaluate how we do our processes, and then help us tailor a solution to help us meet our objectives.”

This shift helped MSC align its physical systems with the growth of its inventory and customer needs, all while working within the same facility footprint.

Improving the Workday: Prioritizing People Alongside Performance Through Material Handling Automation

One of MSC’s primary goals for the AutoStore project was to create a better work environment for the people running the operation. The shift to distribution center automation brought meaningful change for employees used to repetitive lifting, walking long distances, and managing inventory by hand.

“Before working with Bastian, all of our processes were very manual and taxing on our associates,” said Darin Russell. AutoStore introduced a more streamlined system where employees could stay in one place while the inventory came to them. This reduced physical strain and improved overall workflow.

As employees adjusted to the new system, many found new growth opportunities. “They have more options, they learn new skills,” said Robert Smith, Customer Fulfillment Center Manager at MSC. “They’ve really enjoyed it.”

Technology also played a role in making the transition easier. MSC’s team noted how intuitive the software layer was for their associates. “Exacta is Bastian Solutions’ [intralogistics] software that’s really flexible. It’s simple to use for them,” Smith said. “It meets the needs of all of our associates.”

The changes supported productivity and helped create a more sustainable work experience for teams on the floor—an outcome that MSC prioritized from the beginning.

Customer Experience: Faster, Smarter Order Fulfillment With Automation

Improving the experience for MSC’s workforce also led to a stronger customer experience. With AutoStore in place, the company saw clear gains in speed and efficiency, two critical factors in fulfilling orders on time.

By automating key steps in the picking process and reducing manual touchpoints, MSC was able to streamline order flow. “Orders are getting out the door faster, and customers are receiving their orders quicker,” said the Bastian Solutions project manager. This improvement came from greater consistency and a simplified workflow, not just new equipment.

Customer Fulfillment Center Manager Robert Smith shared that MSC achieved nearly 40 percent labor savings while increasing throughput. With more volume moving through the system and fewer slowdowns, customer expectations were easier to meet, even during peak demand.

Automation also introduced more flexibility to the operation. As team members adapted to the new system, they learned additional skills and moved more confidently between roles. This versatility allowed MSC to better respond to changes in order volume without disrupting service quality.

Collaborating with Bastian Solutions to Deliver Warehouse Automation Success

From the early planning stages through final implementation, Bastian Solutions worked closely with MSC to ensure the project met their goals. The partnership was built on clear communication, hands-on collaboration, and a shared focus on making the system work for operations and employees.

Darin Russell, Senior Director of Supply Chain Engineering Services at MSC, emphasized the value of that support. “We had monthly meetings to make sure our objectives were being met, our needs were being met, [and] the project was going very smoothly.”

Training played a central role in the system rollout. Bastian’s team worked directly with MSC staff to ensure employees were prepared to use both the AutoStore system and the Exacta software that powered it. “Their team members were top notch,” said Robert Smith, Customer Fulfillment Center Manager. “Any questions we had, they were able to answer them. They were very thorough and supported any needs that we had.”

That support didn’t go unnoticed. When asked about working with Bastian, Customer Fulfillment Director Mindy Wright summed it up simply: “I believe the solution that was implemented was exactly what we needed for our business… I would say absolutely work with Bastian Solutions.”

How Automation Improved Fulfillment Performance at MSC

For MSC, the AutoStore implementation delivered measurable improvements across operations, workforce experience, and customer service. Highlights include:

• Labor savings of nearly 40%, allowing the team to do more with fewer manual processes
• Increased throughput, helping fulfill more orders in less time
• Improved employee experience, with ergonomic workstations and less repetitive movement
• Cross-training opportunities, giving employees the chance to learn new skills
• Faster order fulfillment, resulting in improved customer satisfaction

Bastian Solutions played a key role in making those results possible. As a material handling automation integrator, Bastian helps organizations evaluate their current operations and identify the right automation solutions to meet their goals. Whether you're implementing automation for the first time or upgrading existing systems, Bastian’s team can help guide the process from concept to completion.

Contact a Bastian Solutions engineer to learn more or start a conversation about your next project.

View the full case study and associated technology.

Author: Brent Davis, Sheila Dooley