Distribution Centers Explained (2024)

Anyone who has ever engaged in ecommerce can attest to how easy it has become to purchasegoods online. Distribution centers are a major reason any online purchasing has become sopractical, not to mention why shipping times have become faster than ever before. Thesefacilities are used to store goods before they're shipped off to end customers, whetherthe customer is an individual consumer, a wholesaler or a retail establishment. Distributioncenters rely on strategic locations and efficient practices to accelerate order delivery andincrease company profitability.

What Are Distribution Centers?

Distribution centers are logistics facilities that store finished goods before they'repicked and packed to fulfill customer orders. In a sense, they can be thought of asspecialized, strategically located warehouses. Distribution centers play a key role in thesupply chain, particularly with regard to helping fulfill customer orders more quickly andaccurately while keeping associated costs down.

Distribution centers can be run and managed differently depending on a business's needsor structure. For example, some retail companies build and manage their own distributioncenters, while some partner with third-party logistics (3PL)providers. Other companies center their entire business model around beingspecialized distribution centers that sell to other companies, such as wholesale fooddistributors that supply to restaurants and hospitality companies.

Distribution center vs. warehouse:

Because they tend to look similar and distribution centers tend to take on warehousingcapabilities like goods storage, "distribution center" and "warehouse"are often used interchangeably. But fundamental differences exist between the two, with eachfacility type designed to handle different operations.

  • Warehouses are spacious buildings in which large quantities of goodsare stored, often long term. Goods stored in warehouses are usually supplied tomanufacturers or wholesalers rather than directly to consumers. It's uncommon forwarehouses to actively handle order processing and fulfillment tasks in their day-to-dayoperations.
  • Distribution centers are more like all-in-one logistics operations thatstore, pick, pack and ship products to fulfill customer orders — either to retaillocations or directly to individual consumers. Distribution centers are commonly used byonline retailers and ecommerce companies. Compared with warehouses, distribution centerstend to focus less on long-term storage and more on the flow of goods. This calls forprocesses that can keep fulfillment speeds up and costs down.

Key Takeaways

  • Distribution centers form the basis of the modern supply chain network.
  • They're used to store, pick, pack and ship products to fulfill customer orders.
  • Facility organization and careful planning are keys to running a streamlineddistribution operation.
  • The right technology, from warehouse automation technology to enterprise resourceplanning (ERP) solutions, can also help distribution centers run efficiently.

Distribution Centers Explained

Distribution centers essentially infuse traditional warehouse practices with the capabilitiesof a fulfillment center to establish storage solutions that help companies quickly sendgoods to their customers. Specifically, distribution centers store large amounts ofinventory and are located closer to their eventual delivery locations, making shippingfaster, easier and more cost-effective. For example, a retailer might sell thousands ofproducts from hundreds of suppliers, if not more. By having its own network of distributioncenters or working with a 3PL, the retail company can store all sold goods from allsuppliers in centralized locations. Instead of replenishing each retail storelocation's shelves by ordering from each supplier (which requires several shipments ofgoods coming from several locations), each retail store can receive one lump shipment fromthe nearest distribution center.

Distribution center management typically combines traditional warehouse best practices, suchas inventory management, space optimization and quality control, with fulfillment practices,like order processing and product return and exchange workflows. To enhance the process,many companies use technology solutions, including automation or mobile data collection.

Why Do Companies Use Distribution Centers?

At some point, a business may begin to carry enough products or serve enough customers thatit outgrows its storage space. The larger a business and its customer base become, the morechallenging it is to keep up with demand. To grow and expand sustainably while effectivelymanaging warehouse operations and providing top-notch customer service, the business'snext step might be to open a distribution center or work with a 3PL. This centralized,logistical hub aims to efficiently consolidate orders, streamline operations and improvecustomer experience.

Distribution centers can be selected in strategic locations that reduce the cost and time ittakes to get a product to its end destination. They can store larger quantities of goods forlong periods of time, enabling companies to pay bulk rates for extra goods in advance. Andwhen enough goods are on hand, it helps ensure that the right products are always availablewhen orders are ready for picking.

How Distribution Centers Work

There's no one set way a distribution center operates; that will depend on the nature ofthe industry. For example, some distribution centers ship items only to stores; others mayfocus on direct-to-consumer purchases and some do both. A distribution center's dailyoperations are often driven by demand, unlike a more traditional warehouse, which stores asmuch of as many products as it can.

Regardless of the industry, suppliers or manufacturers typically ship their products directlyto the appropriate distribution centers, where they are received and put away in theirappropriate storage locations. When it's time for delivery, employees handle thenecessary fulfillment and logistics processes. In other words, the appropriate items arepicked from stock, packed and shipped every time a customer order is made. An alternativeapproach is a distribution center's use of cross-docking — a strategy in whichfast-moving inbound freight is immediately moved to a separate outbound dock to bypass theneed for storage and therefore accelerate the delivery process.

Smaller companies may choose to outsource their distribution networks to a dedicatedlogistics organization, while larger companies are more likely to own and run their owndistribution networks that are designed to transport goods from manufacturers or wholesalersto retailers or consumers. Large-scale companies may have several distribution centerslocated throughout the store's markets, with each distribution center either serving anestablished number of stores or a set geographical region if it's a direct-to-consumer operation.

A key part of the process is distribution management, which aimsto oversee the transport of products from supplier or manufacturer to wholesaler, retaileror end customer. This can include activities and processes like raw goods vendor management,warehousing, inventory management and supply chain management.

Benefits and Drawbacks of Using a Distribution Center

When run well, distribution centers play a critical role in supply chain efficiency andbusiness growth. For example, they can keep costs down by decreasinginventory carrying costs, since distribution centers tend to deal with goods thatare stored for short periods of time, unlike warehouses. Another benefit is shipping speed:A company with several distribution centers in a mass-market area can potentially deliver tocustomers faster, saving on shipping costs and boosting customer satisfaction. Furthermore,by centralizing the order fulfillment process, distribution centers can fulfill largerorders with many SKUs faster. This is much more effective than placing multiple orders withdifferent suppliers to fulfill a single customer order.

Yet distribution centers are not without some drawbacks. These operations must be run tightlyto ensure efficient operation — any small, overlooked detail can potentially causeunforeseen problems and bottlenecks. Miscommunications regarding picking and packing canlead to order-fulfillment issues, and disorganized inventory or warehouse layouts can makeit hard for workers to do their jobs efficiently. Similarly, minor quality control issuescan lead to recalls that not only cause a company to lose money but also can harm itsreputation. What's more, distribution centers aren't immune to natural disruptionsthat can negatively impact operations, such as severe weather events; human disruptions likestrikes, riots or wars; transportation disruptions due to accidents or maintenance; andconsumer demand fluctuations, such as those due to recessions or depressions — all ofwhich can negatively impact operations.

Examples of Distribution Centers

There are a few main types of distribution centers, including those that deliver directly toretail companies, only to individual consumers or to both. Orgill, for example, is anindependent distributor that partners with vendors and manufacturers to supply hardware andhome improvement products to thousands of retail stores globally. The company has sevendistribution centers across North America.

Similarly, Sysco is a company that distributes food products and kitchen equipment torestaurants, food service companies, health care and educational facilities, and hospitalitycompanies. Sysco has over 320 distribution facilities around the world. On a smaller scale,Baldor Specialty Foods is a specialty food distributor with a handful of locations thatenable the company to directly service restaurants, hotels and similar companies in theNortheast and mid-Atlantic regions of the U.S.

Other companies, particularly those focused on ecommerce, deliver only to individualcustomers. Amazon is a well-known example. The company has more than 100 active so-called"fulfillment centers" across the U.S. alone. Sellers ship their items to thesefulfillment centers, where they are stored until workers pick, pack and ship them to fulfillcustomer orders. Amazon's distribution centers generally range in size from 600,000 to1 million square feet.

Nike is another example. It has over 50 distribution centers around the world, enabling thecompany to sell directly to consumers, wholesalers and retailers. The company has sixprimary distribution centers in the U.S., the largest of which is a 2.8 million-square-foot facility located in Tennessee, with 33 milesof conveyor belts, 73 outbound doors and 96 receiving spurs.

Types of Storage Used at Distribution Centers

Items delivered to distribution centers are stored according to product characteristics andquantities. Specialized equipment is used to handle different types of storage containers.Following are five common types of storage containers used in distribution centers.

  • Intermodal containers, commonly known as shipping containers, areused to move large quantities of goods. They're called "intermodal"containers because they can be used across different transportation methods,including ship, rail and truck.

  • Bulk boxes, also known as bulk bins, are pallet-sized boxes used toship and store bulk quantities of an item. Bulk boxes are typically made ofcorrugated cardboard, wood, aluminum, steel or plastic. Some might have plasticliners to protect the contents of the box. Contents are usually loose parts, such asscrews, bolts or loose apples, or granular materials, like powders.

  • Pallets are flat, level transportation structures that stablysupport heavy loads of goods and can be easily moved with implements like palletjacks and forklifts. Pallets are most commonly made of wood or plastic and canhandle a load of one ton. Pallets can be stored on the floor, stacked or stored onpallet racking.

  • Cases, also known as cartons, are boxes containing many items. Acase of wine, for example, contains 12 individual bottles. Cases are often storedand transported on pallets but can also be stored in warehouse racking.

  • Totes are reusable containers similar to bulk boxes. They'reoften stored on pallets and are used to hold and transport goods, often liquids,semi-solids or solids. A common type of tote is an intermediate bulk container(IBC), which is a cube-shaped, reusable container often used to carrypharmaceuticals, grains, chemicals, liquids, food ingredients and sand.

Distribution Centers & Technology

Many successful modern distribution centers rely on various technologies to streamlineoperations, from receiving and storing items to picking and packing them for shipping. Thesetechnologies range from automated robotic equipment to management software that relies onautomation and cloud computing. Here are a few warehouse automationtechnologies commonly found in distribution centers.

Automated storage and retrieval systems (AS/RS)

Are a type of goods-to-person (GTP) fulfillment technology that automatically stores andretrieves products. AS/RS technologies include cranes, carousels, vertical lift modules(VLMs) and shuttles. High-volume warehouses, especially those with space constraints, areusually more likely to benefit from AS/RS systems.

Barcode and RFID systems

Help companies reduce the need for paper management, saving on storage space and eliminatingsome time-consuming steps during the put-away and fulfillment processes. For example,instead of workers having to write down or type product or shipment information, they cancarry mobile devices and scan barcodes. This streamlines processes and canreduce human error.

Automatic guided vehicles (AGVs)

Are vehicles that navigate a fixed path throughout a warehouse or distribution center, oftento transport inventory from receiving to storage locations. Autonomous robotic forklifts arean example of an AGV designed to transport pallets without the need of a human operator.They are most effective in spacious environments that require repetitive tasks.

Distribution Center Processes

Distribution centers handle receiving products from manufacturers or wholesalers, organizingthem and shipping them to their final destinations as quickly as possible. This requirescarefully monitoring inventory levels so as to keep operations running as efficiently aspossible. The three major processes that occur in most, if not all, distribution centersare:

Receiving goods.

Distribution centers first receive goods, usually from suppliers, manufacturers or otherlong-term storage warehouses that belong to the company. Trucks arrive and are unloaded at areceiving dock. The process can be made faster using equipment like pallet jacks andforklifts, as well as mobile technology like scanners. At this point, employees should makesure all received items accurately match their order and are of appropriate quality.

Storage.

After deliveries are unloaded, inspected and scanned in, they're stored in securelocations according to the distribution center's stock management strategy, such asfirst in, first out (FIFO) or last in, first out (LIFO). Conveyors may be used to moveorders from receiving to storage, where, for example, they're placed on pallet racks.Warehouse workers should be keeping track of stock. Temperature control is important forcertain industries. Some distribution centers cross-dock, eliminating the need to transportitems to a longer-term storage location within the distribution center. Cross-docking istypically an effective solution only for distribution centers that rapidly turn overinventory.

Order fulfillment.

Once a customer places an order, it must be picked, packed and shipped. Depending on the sizeand scope of the distribution center, picking and packing might be performed by the sameindividuals, or there may be dedicated picking, packing and shipping teams. Warehousemanagement systems (WMS) can be used to automatically assign an order picking strategy that emphasizesaccuracy and efficient workflow, such as batch picking, wave picking or zone picking. Items are packed and thenshipped.

Depending on the nature of the operation, some distribution centers will also manage returns.Distribution centers that process returns in-house typically must communicate with thecustomer initiating the return and, once the item is received, restock it or refurbish it,if necessary.

Costs of Using Distribution Centers

Opening a distribution center can be costly in the short term, but long-term benefits tend tooutweigh initial expenses. This is because distribution centers aim to maximize efficiencywhen it comes to receiving, storing, packing and distributing goods — translating tolower inventory carrying costs, lesschance of stockouts and less chance of losing customers due to prolonged fulfillmenttimes.

Of course, there are costs associated with building and operating a distribution center, andthey can differ depending on whether a company runs its own distribution center or uses athird-party distribution service. The costs of building a distribution center depends onvarious factors, such as size, location and type of building. A distribution center built inCalifornia or New York will likely be more expensive than one in Alabama, for instance. Amajor company with a large distribution operation might expect to spend millions onconstruction alone. Other costs to consider include permits, planning costs, material costs,engineering costs, security system, legal fees and taxes.

Operating costs typically include those associated with handling products, such as the laborand equipment involved in receiving, put-away, picking and shipping; the fuel andelectricity to handle such equipment; plus upkeep. Storage costs include inventory carryingcosts; administrative costs like clerical and IT-associated costs; supplies, insurance,office expenses and general management; and variable costs like labor.

How to Organize Your Distribution Center

No matter the type of distribution center, all have three core areas: the receiving dock,storage and shipping. No surprise, these areas are noted to be some of the most congestedareas in a warehouse — and congestion can lead to bottlenecks that cause a decline inproductivity. On the other hand, an optimized distribution center layout that creates aseamless flow of goods and people from receiving to shipping can help poise teams forsuccess by increasing productivity, improving accuracy, saving time and prioritizing safety.The following tips can help any distribution center, regardless of industry, capitalize onorganization.

  1. Carefully consider layout.

    Categorize each area of the distribution center by its function, such as receiving,shipping, packing and storage. When doing so, it's a good idea to keep thepacking area as close to shipping docks as possible. A staging area in the receivingzone can help provide the space required to unload vehicles and efficiently check inorders. Floor plans likely depend on the size of the distribution center. Smallerones that receive goods infrequently or only ship weekly may be able to keepshipping and receiving bays side by side without risking traffic jams, whereaslarger operations will perform better with multiple discrete receiving and shippingbays.

  2. Don't forgo safety and security standards.

    Inventory should be strategically stored not only to maximize efficiency but to meetsafety and security standards. This also includes ensuring that aisles are wideenough to safely accommodate both foot traffic and pallet jack and forkliftmovement, as well as any other automated technologies in use. This can help maintainsafety standards while preventing traffic jams.

  3. Utilize vertical space.

    Racking systems are useful for stacking products as high as safely and efficiently aspossible, maximizing storage space — but be sure not to build racking higherthan allowed by manufacturer specifications or overload weight limits. Consider waystechnology can maximize use of vertical space, too. For example, AS/RS systems maybe able to reach higher than forklifts. Efficient heights for pickers must also beconsidered. Try to keep popular items waist-to-shoulder height so pickers don'tneed additional equipment like forklifts or stepladders to reach them.

  4. Don't be afraid to reorganize inventory.

    Frequently purchased products should always be easiest for pickers to access, whichmay mean the need to reorganize the distribution center from time to time. Forexample, a distribution center that carries seasonal items, like Christmasdecorations, may benefit from moving those items closer to picking locations towardthe end of the year and moving summer items to less-frequented storage locations.

  5. Keep it clean.

    Routine cleaning can help keep a distribution center organized and easy to work inand create a sense of calmness, all of which may increase employee job satisfaction.Consider adding a cleaning checklist with daily, monthly and semimonthly cleaningtasks, from sweeping and regular decluttering to deep cleaning and equipmentmaintenance tasks.

  6. Optimize for automation technology.

    Automation-focused distribution centers might benefit from different layouts thanthose used by centers that rely on strictly manual processes. Thus, a company thatplans to incorporate automation should work with automation solution vendors as wellas architects or contractors to understand and implement any unique requirements.For example, a distribution center that plans to use a conveyor system suspendedfrom the ceiling should consider the load-bearing capacity of ceiling beams beforeinstallation.

Distribution Center Planning

When planning a distribution center, it's important to consider location. Ideally,distribution centers should be located near main highways or roadways, making it easy fortrucks to deliver or pick up products. They also are usually established near majorpopulation centers, near ports or in industrial hubs. Having multiple distribution centers,such as one on the East Coast and the other on the West Coast, can help a company distributegoods to all customers faster and cheaper. Multiple inventory locations can also help acompany mitigate risk if, for example, a natural disaster occurs in one area.

Beyond location, conventional modern distribution centers might plan to include some or allof the following functions:

  • Goods in.

    Also known as goods receipt or goods receiving, this warehouse function refers to thephysical movement of goods into the warehouse from external suppliers. Goods inusually occurs in a receiving bay. Workers might use specialized equipment, such asforklifts, pallet jacks and conveyors, to unload containers and carry in materials.At this point, goods are checked for correct quality and quantities.

  • Bulk storage.

    This area of a warehouse controls larger orders, such as those that only contain fullcartons or boxes. Bulk quantities might be stored in warehouse racking and requireworkers to use forklifts or other materials-handling equipment to move, store andpick full pallets of goods.

  • Shipping.

    Shipping teams control the flow of orders out of the distribution center. Workersmight pack customer orders and prepare them for shipping, and also build pallets.Distribution centers that deal with international shipping might also have exportteams dedicated to getting goods ready for an international journey, includingproper documentation and preparation of appropriate shipping containers.

  • Production.

    For some distribution centers, especially for companies that pack wholesale bulkshipments, it's important to have a production team to repack goods asnecessary. A supermarket, for example, might pack raw items with their ownpackaging. Such production can also be managed by third parties or at productionfacilities, instead of at a distribution center.

  • Quality assurance (QA).

    QA teams are responsible for ensuring that all goods meet necessary standards. To doso, QA teams might conduct periodic spot checks of random samples of incoming goods,goods in storage and outgoing products.

  • Transportation.

    Transportation teams arrange and coordinate shipments to and from the distributioncenter. Some companies might partner with third-party transportation companies,while other larger companies might have their own private transportation networks.

  • Specialized departments.

    Depending on the nature of the items being stored and distributed, companies may alsobenefit from dedicated product departments. A food distributor might have separaterefrigerated and non-refrigerated sections, and each department may require its ownshipping and receiving bays.

Job Types in Distribution Centers

Distribution centers have a variety of departments. While the most obvious might be thosethat manage direct, hands-on labor, such as the crews that receive shipments, pick ordersand pack them, distribution centers also have indirect labor departments, such as humanresources, maintenance and facilities operations, finance and accounting, management andmore. Common jobs in distribution centers can include:

  • Unloaders and receivers who unload trucks, break down pallets, scan in inventory andcheck the quality and quantity of received items.
  • Put-away workers who store received items on warehouse shelves and in racking.
  • Order fillers who pick and pack items according to pick lists and prepare them forshipment to their end destination.
  • Supervision and management, such as managers and supervisors who oversee the warehouseand floor, supervise labor and create and manage employee scheduling.
  • Human resources workers, who handle tasks like payroll, employee benefits andonboarding.
  • Facility operations, housekeeping and maintenance teams that keep the space clean andtidy and make sure machinery is functioning properly.
  • Inventory management teams that oversee inventory levels by recording daily deliveries,tracking shipments and ordering more inventory as necessary.
  • Asset protection teams that provide security by making sure items are stored safely andsecurely.
  • Quality control teams that verify that all incoming, outgoing and stored goods are up toestablished quality standards.
  • Technology teams that are responsible for supporting and maintaining IT systems andkeeping them secure. An IT department can be especially valuable for organizations thatembrace cloud technology and other tools that rely on the Internet, such as enterprise resource planning (ERP)systems.

AB 701: California Distribution Center Law Regulates Product Quotas

In September 2021, California Gov. Gavin Newsom signed into effect AB 701. The law, whichwent into effect Jan. 1, 2022, specifically regulates the use of production quotas indistribution centers and warehouses. For example, AB 701 states that:

  • Employers are prohibited from requiring work meets quotas that prevent them fromcomplying with health and safety laws, such as employees' taking rest or mealbreaks.
  • Employers must provide a written description of each quota an employee is subject to,plus any potential consequences that could result from not meeting the quota.
  • Employers are prohibited from taking adverse actions against employees who fail to meetundisclosed quotas.

The law specifically targets employers that use "warehouse distribution centers"”and have control over the wages, hours or working conditions of 100 or more employees at asingle distribution center, or 1,000 or more employees at one or more distribution centersin the state of California. Employee counts must also include workers provided through thirdparties like staffing agencies, provided the employer exercises control over their wages,hours or working conditions.

The term "warehouse distribution center" applies to any establishment primarilyengaged in operating storage facilities and merchandise warehousing or that are primarilyengaged in selling merchandise using non-store means, such as ecommerce or catalogs.Specifically, AB 701 cites four North American Industry Classification System (NAICS) codesto define a "warehouse distribution center":

  • 493110: General Warehousing and Storage.
  • 423: Merchant Wholesalers, Durable Goods.
  • 424: Merchant Wholesalers, Nondurable Goods.
  • 454110: Electronic Shopping and Mail-Order Houses.

However, it's important to note that under the law, it's irrelevant which NAICScode is assigned to your establishment. Instead, if any of the above definitions could applyto your business, your warehouse or distribution center qualifies.

Optimize Your Distribution Center With NetSuite

Running a distribution center — or several — requires the synchronization of manymoving parts. This can be best handled by advanced tools such as those offered by NetSuite,including NetSuite InventoryManagement, NetSuite Warehouse Management and NetSuite Enterprise Resource Planning, which connectsand centralizes the various applications in a single, integrated suite. When implementedproperly, these tools allow entire distribution center teams and companies to manageinventory, from scanning barcodes when products are received to developing automated picklists to connecting with customer relationship management (CRM) tools thatautomatically provide tracking information for customers. In turn, these solutions can helpreduce human error and improve efficiency, thereby leading to cost savings — andgettingproducts to their end destinations faster.

Conclusion

Distribution centers play a key role in the modern supply chain. They focus on receivingproducts from different locations and vendors, organizing them and storing them safelybefore shipping them to their end destination, whether that is a retail location or endconsumer. Distribution centers are typically located near highways and roadways close tomajor metropolitan areas to expedite delivery times. Using the right technology, such asinventory management, warehouse management and ERP solutions, can help distribution centersoperate more efficiently.

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Distribution Center FAQs

What do distribution centers do?

Distribution centers are logistics facilities that receive goods from suppliers and storethem until they're ready to be picked and packed to fulfill customer orders.Distribution centers combine warehouse processes like item storage with fulfillment center operations tohelp companies ship goods to customers as quickly and efficiently as possible.

How big are distribution centers?

Distribution centers vary in size, depending on the nature and needs of a business.Micro-fulfillment centers might be less than 10,000 square feet, whereas some of the largestdistribution centers in the world exceed 1 million square feet.

What's the difference between a distribution center and a warehouse?

Though they may look similar and share processes like storing goods, distribution centersincorporate order fulfillment processes while warehouses usually simply store goods, oftenfor extended periods of time. Distribution centers typically handle the shipping of goodsdirectly to retail stores and/or consumers, while the goods stored in warehouses are moreoften supplied to wholesalers or retailers. Items are often stored in distribution centersfor less time than in warehouses.

What are examples of distribution centers?

There are a few main types of distribution centers, whose differences reflect the model ofthe business. For example:

  • Companies with physical locations that have their own distribution centers to helpdeliver products to stores and customers more efficiently.
  • Ecommerce companies that rely on distribution centers to fulfill customer orders.
  • Companies that, by nature, are distribution centers. This can include wholesalecompanies that receive goods directly from manufacturers or vendors and distribute themto retail locations, or food distribution companies that ship fresh produce and kitchengoods to restaurants and hospitality companies, for instance.
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