Federal-Mogul Corporation is a global supplier of trusted brands and products to automotive manufacturers, as well to power generation, aerospace, marine, rail and industrial applications. 
Federal-Mogul has 41.000 employees spread out over 33 countries. The company focusses on OEM and after-market products. 


  • Data analysis
  • Material flow mapping current and future state
  • Logistics solution design (multiple alternatives)
  • Economic feasibility of logistics solutions

Logistics feasibility study for new DC

At the time of the study:

The existing DC in Bradford (UK) is an outdated building that limits the logistics operations efficiency and future growth opportunities. In order to support further growth and to improve the cost efficiency of the intralogistics processes, Federal-Mogul asks to perform a logistics feasibility study.


Engineer an optimal logistics concept for a greenfield plot of land and investigate the related feasibility taking into account following requirements:

  • building restrictions of optional new plot;
  • improvement of order lead time;
  • significant reduction of operational costs;
  • reduction of maintenance costs for the new building.


Two logistics concept designs were engineered: a manual warehouse containing traditional pallet racks, flow racks and shelves and a highly automated alternative containing 2 ASRS pallet cranes with pick-to-belt conveyorconnection and a pick-to-light zonepicking solution driven by 2 ASRS miniload cranes.
Detailed CAPEX and OPEX budgets were projected for both concept designs and were integrated in the business case calculation.

Curious what we can do for you