Case Studies

Case Study: Direct Store Delivery Network Optimization Across 1,150 Stores

CJ Logistics — Thu, 09 Jul 2026 19:39:42 GMT

A consumer packaged goods retailer with a 1,150-store DSD network

THE SITUATION

A CPG retailer was consolidating two distribution centers into a single, more centralized location over a 12-month period — and needed to re-optimize temperature-controlled direct store delivery (DSD) across all 1,150 of its stores in the process. The complexity lived in the details: stores didn't share a single delivery profile. Many required lift gates, inside delivery, or specific delivery windows, so a one-size transportation plan was never going to work. The retailer needed a model that honored every store's requirements while capturing the efficiency the consolidation was meant to deliver.

OUR SOLUTION

CJ Logistics engineered a hybrid transportation model that matched the right mode to the right lane rather than forcing everything through one method. The design combined multi-stop truckload, LTL routed through pool-point hubs, and optimized dedicated fleet service — with Infios fleet optimization used to cut total weekly trips while still hitting each store's strict delivery windows and special-handling needs. The newly consolidated DC location was structured to leverage shared resources across business units and to position the retailer for future growth, so the network gained headroom rather than simply shrinking.

RESULTS

Case Study: Large-Scale JIT / JIS Inbound, Consolidation & Sequencing

CJ Logistics — Thu, 09 Jul 2026 19:36:06 GMT

A major automotive manufacturer (Monterrey, Mexico production campus)

THE SITUATION

A major automotive manufacturer running a large production campus in Monterrey, Mexico needed a partner to manage the inbound logistics and consolidation operation that keeps the line running. Modern vehicle assembly depends on parts arriving exactly when and in the exact order they are needed — just-in-time (JIT) and just-in-sequence (JIS) — and any gap in that flow stops production. The challenge was coordinating parts from a base of more than 15 vendors into a single, reliable feed to the plant, at the scale of a full manufacturing campus.

OUR SOLUTION

CJ Logistics took on a 36-million-square-foot logistics operation encompassing all parts transportation across the campus and the movements among 15-plus vendors that supply it. At the center of the operation, a 103,333-square-foot consolidation facility served as the staging and value-add hub: CJ Logistics performed kitting and assembly there, grouping and pre-building parts before shuttling them to the plant in the precise sequence the line required to support JIT and JIS production. Running an operation at that scale and tempo demanded significant dedicated transportation capacity — a fleet of 106 trailers, 54 tractors, and 9 box trucks, with roughly 130 drivers operating per day to keep parts moving continuously between vendors, the consolidation center, and the assembly line.

RESULTS

Case Study: Greenfield Temperature-Controlled Facility, Designed and Delivered End to End

CJ Logistics — Thu, 09 Jul 2026 19:32:07 GMT

A Fortune 20 healthcare company handling medical & surgical devices

THE SITUATION

A Fortune 20 healthcare company handling both branded and private-label medical and surgical devices needed to expand its operations and diversify its inbound port locations — reducing exposure to congestion at any single gateway while adding capacity for future product launches. Rather than commit to a location on instinct, the company asked CJ Logistics to determine the optimal network configuration through rigorous modeling, then to actually build and run the result.

OUR SOLUTION

CJ Logistics began with the data, gathering daily transactional volumes and detailed customer requirements and running them through industry-leading network design software to pinpoint the optimal geographic location for a new East Coast distribution center. The analysis weighed the full cost picture — transportation, warehousing, and inventory costs alongside real estate, local wage levels, regulatory factors, and available incentive credits — so the recommendation balanced service and total cost rather than any single variable. CJ Logistics then managed the entire build-out as a turnkey project: construction, facility layout, rack installation, capital equipment procurement, the Rx and medical-device licensing that healthcare distribution requires, IT systems and hardware, and full staffing. The customer received a fully operational, compliant facility without having to assemble and manage the project itself.

RESULTS

Case Study: Standing Up Drop-Ship Fulfillment Inside an Existing B2B Operation

CJ Logistics — Thu, 09 Jul 2026 19:27:00 GMT

An established consumer packaged goods partner

THE SITUATION

An established CPG partner watched online B2C demand climb steadily and needed to scale direct-to-consumer drop-ship fulfillment to match it — without compromising the service levels of its existing business. The catch was that there was no appetite to build a separate ecommerce facility; the new B2C capacity had to live inside the framework and infrastructure of the existing B2B distribution center, where order profiles, pick patterns, and packaging requirements look very different from wholesale.

OUR SOLUTION

CJ Logistics solved it by building a “warehouse within a warehouse.” Inside the existing DC, the team created distinct processes for B2C — separate replenishment flows and segregated inventory tracking so ecommerce orders never competed with B2B fulfillment for the same stock or attention. A dedicated area was re-zoned around the smaller pick profiles that drop-ship demands, with the faster-moving SKUs slotted close to a dedicated parcel pack-out area to minimize travel and speed throughput. On the systems side, a dedicated IT integration team ensured order details, label information, and status confirmations transmitted accurately between the customer's channels and the DC, and the team mapped promotional and marketing-material inserts into the SKU mix so brand and campaign requirements were handled inline rather than as exceptions.

RESULTS

Case Study: High-Value Direct-to-Consumer Service Parts Fulfillment

CJ Logistics — Thu, 09 Jul 2026 19:21:28 GMT

A consumer electronics company expanding into service-parts fulfillment

THE SITUATION

A consumer electronics company expanded its business to include service-parts fulfillment — a demanding profile on every dimension. Its roughly 3,000 SKUs were high in value and prone to damage, so handling had to protect fragile product at every touch. Service commitments required same-day shipping on 75% of orders, leaving little slack in the process. And the sales cycle was highly seasonal, with space requirements swinging by nearly 40% during peak, meaning the operation had to flex dramatically without losing speed or accuracy.

OUR SOLUTION

CJ Logistics' engineering team designed the operation around those constraints rather than retrofitting a standard process. They customized an each-pick module engineered for both efficiency and accuracy, structured to maximize productivity by minimizing re-handling during the pick — which simultaneously reduced the opportunities for the damage these high-value items were prone to. On the systems side, the team enabled unit-pick batching paired with a customized label and packing slip, and integrated Logistyx to optimize parcel rating at pack-out, controlling shipping cost on every order. The result was a purpose-built operation able to absorb the seasonal swing and hold to the same-day commitment.

RESULTS

Case Study: Warehouse Takeover, Expansion & Performance Turnaround

CJ Logistics — Thu, 09 Jul 2026 19:06:06 GMT

A leading global tire manufacturer

THE SITUATION

A leading global tire manufacturer had been running its U.S. warehousing in-house, but the operation showed the strain: performance was tracked through only a narrow set of metrics, and employee turnover was high enough to threaten consistency and reliability. In 2018, the manufacturer turned to CJ Logistics not only to take over management of the operation as a third-party logistics provider, but to expand and relocate it — moving to a larger facility while improving the stability and performance the in-house team had struggled to sustain.

OUR SOLUTION

CJ Logistics assumed full 3PL management and relocated the operation from Rancho Cucamonga to a larger facility in Fontana, California, expanding capacity by roughly 200,000 square feet — from about 500,000 to roughly 700,000 square feet. Critically, the transition kept the existing workforce intact: CJ Logistics successfully transferred the original staff to the new site rather than starting over, preserving institutional knowledge. To attack the turnover problem at its root, CJ Logistics introduced regular employee engagement and appreciation programs, treating workforce stability as an operational priority rather than an afterthought. The team modernized the material-handling fleet through its Crown Equipment partnership and broadened performance management well beyond the customer's prior focus on inventory accuracy — building out KPI tracking across inventory, inbound, and outbound performance so the whole operation could be managed by the numbers.

RESULTS

Case Study: A Decade-Long Strategic Partnership Built Around Growth

CJ Logistics — Tue, 30 Jun 2026 16:51:04 GMT

A Fortune 500 packaged-food company with a multi-brand portfolio

THE SITUATION

A Fortune 500 packaged-food company with a growth-by-acquisition strategy needed more than a warehousing vendor — it needed a supply chain partner that could absorb new businesses repeatedly without disrupting service, across product lines spanning cold, frozen, and temperature-sensitive goods. Each acquisition brought its own facilities, systems, and ways of working, and the company needed those folded into a single, optimized network on a recurring basis while day-to-day distribution continued uninterrupted.

OUR SOLUTION

Beginning in 2015, CJ Logistics built a partnership designed to flex with the customer's M&A pace and evolving business-unit strategy. Over the course of the relationship, CJ Logistics executed more than seven seamless M&A integrations, standing up new operations and absorbing acquired ones without service interruption. The partnership modernized the technology backbone — launching BlueYonder warehouse management and MercuryGate transportation management systems — and added physical capacity through greenfield facilities purpose-built for the customer's needs. CJ Logistics managed refrigerated rail assets to support temperature-controlled movement, ran continuous network and transportation modeling to keep the footprint optimized as the business changed, and began piloting AI to drive the next phase of improvement. The work has moved through clear phases — optimization, implementation, and continuous improvement — with each acquisition and initiative handled inside that framework.

RESULTS

Case Study: Lead Logistics Partnership & Network Rationalization

CJ Logistics — Sat, 27 Jun 2026 03:56:56 GMT

A Fortune 500 consumer packaged goods company

THE SITUATION

A Fortune 500 CPG company set out to simplify a supply chain that had grown unwieldy over time. Its network had expanded into a patchwork of facilities — a central distribution center adjacent to a manufacturing plant, a large dedicated export warehouse, and 18 additional warehouses — with freight moving through dozens of carriers coordinated by an in-house traffic department. The complexity was driving up cost and management overhead, and leadership wanted to rationalize the footprint and reduce the number of locations without disrupting service to wholesale customers nationwide.

To get there, the company engaged CJ Logistics as its Lead Logistics Partner (LLP), handing over end-to-end responsibility for the supply chain from central DCs all the way to the customer's wholesale accounts.

OUR SOLUTION

Rather than rebuild the network from scratch, CJ Logistics designed a streamlined model deliberately structured to protect service while taking out cost. The plan retained current regional DC and carrier partners wherever it made sense, mitigating the risk that comes with wholesale change and keeping continuity for the customer's accounts during the transition. The redesign consolidated the footprint from 20 locations down to nine warehouses supported by five crossdock operations. Execution was sequenced carefully: CJ Logistics transitioned 14 buildings over an 18-month window, ordering each move logically so that no part of the network went dark or fell behind on service.

To keep the partnership tightly aligned, CJ Logistics embedded one of its own leaders on-site at the customer's headquarters early in the start-up phase — putting decision-making close to the customer during the highest-risk period of the engagement.

RESULTS

Case Study: Greenfield Healthcare Distribution — From Network Design to Operation

CJ Logistics — Wed, 24 Jun 2026 15:30:19 GMT

How CJ Logistics America took a Fortune 20 healthcare customer from network modeling to a fully operational East Coast distribution center, on time and on budget.

The Situation

CJ Logistics America handles branded and private-label medical and surgical devices and consumables for a Fortune 20 healthcare customer. As the business grew and the need to diversify inbound port locations increased, the customer set out to expand operations and asked us to identify the optimal network options through data-driven network modeling.

Our Solution

Working in close collaboration with the customer, CJ Logistics America ran a full network analysis and identified an optimal site for a new distribution center served by an East Coast port. In the initial analysis phase, we gathered daily transactional data sets and the customer's specific requirements, then used industry-leading design software to determine the best geographic location based on transportation, warehouse, and inventory costs. From there, we recommended an exact build location, weighing available real estate, local wages, regulations, and incentive credits.

Based on our analysis, the customer asked us to bring the solution to life. We managed the complete operational start-up: construction, building design and layout, rack installation, capital procurement, Rx and medical device licensing, IT systems and hardware setup, and full staffing.

The Results

Locating the inbound warehouse closer to the customer's East Coast distribution centers improved transit times and delivered approximately 12% in transportation savings. The East Coast port also lowered inventory carrying costs and opened up additional space for future product launches. Just as important, it strengthened business continuity, giving the customer a reliable alternative when congestion or closures hit other ports. CJ Logistics America delivered the entire project on time and on budget.

Improved transit time

~12% transportation savings

On time and on budget delivery

Case Study: Direct-to-Consumer Service Parts Fulfillment

CJ Logistics — Wed, 24 Jun 2026 15:24:09 GMT

How CJ Logistics America built a custom pick module that handles high-value, damage-prone parts and flexes 40% for seasonal peaks.

The Situation

A consumer electronics customer was expanding beyond its four existing business units to add direct-to-consumer service parts fulfillment. The operation came with three demanding requirements: 3,000 high-value SKUs that are prone to damage, same-day shipping on 75% of orders, and a highly seasonal sales cycle that drives a space-flex need of nearly 40% during peak periods.

Our Solution

Our engineering team designed a custom each-pick module built specifically around the operation's needs for speed and accuracy. The goal was to maximize productivity by minimizing re-handling during the pick process while ensuring every shipment goes out damage-free.

On the systems side, we enabled unit-pick batching with a customized label and packing slip to drive efficiency, and integrated Logistyx to optimize parcel rating at pack-out, controlling shipping cost on every order.

The Results

The custom-engineered solution delivered measurable gains:
40% peak volume variance absorbed at end of month
Enabled continued customer growth
8% parcel and label savings

By engineering the pick module and systems around the customer's specific product profile and seasonality, we gave them a fulfillment operation that scales with demand, protects high-value inventory, and keeps parcel costs in check, all while meeting aggressive same-day shipping targets.