Unpacking Efficiency: GNC’s Automated Depalletization Success
GNC tapped AWL and FANUC robots to automate depalletizing in its Indy center, easing congestion and shifting employees into more meaningful roles.
Challenges
- Existing processes are laborious and ergonomically challenging
- 6-8 associates manually depalletizing daily
- High volume and sporadic product flow led to inefficiencies
Results
Reliable flow of products through facility
Repurposed associates to higher value roles
Increased productivity
Story
Global health and wellness brand GNC was facing increasing congestion inside its Indianapolis, Ind. distribution center. With 15,000-28,000 pieces of product arriving daily, the tough manual task of depalletizing—which fell to six to eight employees—was creating inconsistency and clogging flow within the facility.
Previously held back by the “unknown,” GNC began to see the benefit that an automated system could provide in streamlining operations. AWL—FANUC Authorized System Integrator—partnered with GNC to design and implement two robotic depalletizers with FANUC R-2000 industrial robots to take over depalletization and free up employees for more meaningful work inside the distribution center.
An internal contest was held and the robots were named: Astro is stationed on Side A of the facility, while Blitz lives on Side B. Each day, employees call out to Astro or Blitz to indicate which area they need more product from. But more important than robot names is the trust that’s been earned by GNC with its employees, who understand the many benefits provided by allowing automation to take over the manually labor-intensive work of depalletizing. Resulting in a smoother, more predictable product flow and better use of skilled labor inside the facility.
Our experience with AWL has been good. They’ve been very responsive and have taken all of our constructive criticism to heart and have really helped us through this process.
Bill Monk Vice President of Distribution – GNCFANUC Products Used
R-2000iC/190S
The FANUC R‑2000iC/190S is a short‑arm, heavy‑payload robot designed to boost productivity in compact workspaces where strength and precision are essential.
- Max Payload:
- 190 kg
- Reach:
- 2040 mm
Meet AWL Automation LLC, FANUC Authorized System Integrator
AWL delivers cutting-edge robotic solutions to tackle intralogistics challenges such as improved ergonomics, consistent throughput, and business continuity. With over five years in the intralogistics market and more than three decades of industry experience, AWL integrated over 4,000 robots worldwide—including more than 200 in intralogistics applications.
AWL’s expertise lies in turnkey automation solutions featuring robot-guided AI vision, custom end-of-arm tooling, and a range of modular systems. Built on a proven platform, the tailored solutions cover sorter induction, item picking, random mixed (de)palletizing, stacking, and tote handling.
As a trusted partner from start to execution and beyond, we are supplier-agnostic and leverage the latest technology to drive innovation and sustainability.
AWL is a private company with over 800 employees worldwide. It supports its customers worldwide with facilities in the Netherlands, the United States, Czech Republic, China, and Mexico. AWL ensures its customers’ global productivity by maximizing their processes and operations with smart robotic solutions.
About GNC
GNC is a leading global health and wellness brand that provides customers with a wide variety of science-based products and solution services to Live Well. The brand touches consumers worldwide by providing its products and services through company-owned retail locations, domestic and international franchise locations, digital commerce and strong wholesale and retail partnerships across the globe. GNC’s diversified, multi-channel business model has worldwide reach and a well-recognized, trusted brand. By combining exceptional innovation, product development capabilities and an extensive global distribution network, GNC manages a best-in-class product portfolio.
