Project Background
To support the rapid growth of omnichannel retail in Malaysia, CentralMart Group has built a new, fully integrated smart distribution center in Kuala Lumpur. The facility serves online fulfillment, store replenishment, and regional inventory management.
Although the site is located within Malaysia’s primary logistics corridor, the customer’s former warehouse could no longer meet the demands of business expansion—mainly due to limited storage density, low operational efficiency, labor-intensive workflows, and insufficient safety control.
As the core equipment provider for this project, Dongjian leveraged its extensive experience in Southeast Asia to deliver a complete intelligent warehousing solution covering storage, handling, sorting, and future platform expansion.
Project Scale
- Total Storage Area: 32,000 m²
- Building Height: 18 m
- Integrated Racking System:
- Automated Pallet Racking (AS/RS)
- Very Narrow Aisle (VNA) Racking
- 3-Level Steel Mezzanine
- Carton Flow Racking
- Pallet Locations: 13,500
- Tote Locations: 28,000 (multi-level mezzanine zone)
- Project Duration: 5.5 months (design → manufacturing → installation → commissioning)
Project Highlights
1. Fully Automated Storage with High-Speed Stacker Cranes
- Eight 18-meter twin-mast stacker cranes deployed
- Achieves automatic pallet storage and retrieval (AS/RS)
- Single-pallet handling efficiency increased by 240%
- Full auto-positioning and self-diagnosis reduce manual intervention
- Integrated with WCS/WMS for 24/7 continuous operations
2. High-Safety Racking Structure for Heavy-Duty Logistics
To accommodate a wide range of heavy and bulky SKUs, the system uses:
- Back-to-back pallet rack design for enhanced structural stability
- Thickened uprights and reinforced load beams, ensuring rigidity under full-load conditions
- Mezzanine platforms built with dual-reinforced uprights and anti-seismic bracing
- All racking systems passed third-party structural audits, compliant with MS 1553 & FEM standards
- Structural safety designed for a 10-year service life
3. Space Utilization Increased by 62%
With the combined VNA + AS/RS solution:
- Aisle width reduced by 48%
- Pallet storage density per square meter increased by 62%
- Multi-level mezzanine separates manual picking zones from automated pallet zones, improving operational safety
- 100% accessibility to each pallet position
- The warehouse transitioned from a traditional layout to a high-density intelligent storage facility
Overseas Project Execution Experience
Dongjian deployed its Southeast Asia project management team onsite to provide:
- End-to-end schedule control
- Coordination of overseas installation teams
- Onsite safety management
- SAT/FAT acceptance procedures
- Operator training in English and Malay
During installation, multiple thunderstorms caused unexpected construction delays. Dongjian quickly re-adjusted project sequencing and ensured on-time delivery.
The customer highly recognized Dongjian’s responsiveness:
- All technical issues addressed within 24 hours
- Steel structure and automation equipment finished two weeks ahead of schedule
- WMS/WCS integration passed full acceptance on the first attempt
Project Results & Customer Benefits
| Indicator | Before | After |
|---|---|---|
| Daily Pallet Throughput | 850 | 2,200 |
| SKU Error Rate | 1.3% | 0.08% |
| Warehouse Utilization | 54% | 88% |
| Labor Cost | Baseline | −37% |
| Outbound Response Time | 3.5 hours | 45 minutes |
