- ASICS achieves huge productivity improvement for DC Operations through innovative partnership with ThreeSixty and Vanderlande
- Australian-first technology implementation wins 2025 ASCLA Award for Supply Chain Management
- Complex automation project completed in fully operational warehouse without customer service disruption
ASICS has successfully transformed its Australian distribution operations at its Marsden Park facility in Sydney, achieving massive productivity improvement via an Australian first implementation of advanced automation technology.
The project, named “Kakushin” – a Japanese term that means innovative transformation – was delivered in partnership with automation specialist Vanderlande and supply chain consultancy ThreeSixty Supply Chain Group. The industry leading project has been recognised by the entire supply chain industry, winning the Supply Chain Management award at the 2025 ASCLA awards in Melbourne’s Town Hall in November 2025.
The Journey
ASICS, looking to embrace its business evolution from large wholesale shipments to smaller consumer and e-commerce orders, required changes to its warehousing to efficiently process the growing volume of multi-item orders that characterise modern retail fulfillment.
What makes this implementation different is its integrated omnichannel approach, serving e-commerce, store replenishment, and wholesale operations. Unlike many goods-to-person solutions that focus purely on e-commerce, or cross-dock sorters that operate independently, ASICS has created a fully integrated solution combining all technologies.
Along the transformation journey, ASICS faced significant technical challenges, including fire service problems and discovering that the warehouse slab was not built to automation specifications. This required innovative engineering solutions, ultimately leading to the adoption of High Dynamic Storage shuttle technology – the first HDS implementation of its kind in Australia – instead of the originally planned mini-load crane system. This change not only resolved the structural weight concerns but delivered superior performance, achieving more movements per hour than was required. The HDS buffer system addresses the site’s operational constraints from limited dock capacity, providing essential space and sequencing for palletising stations and dispatch operations.
“At our NSW Marsden Park facility, the new automation system has significantly increased processing capacity and efficiency, with room for future growth. Strong collaboration played a huge role in the success of this project. ThreeSixty’s industry knowledge and expertise enabled us to transform high-level ideas into concrete implementation plans. Their involvement was invaluable throughout the entire process, from developing the business case to managing the complex operational requirements during delivery. Vanderlande’s on-site management and their willingness to adapt their solutions to our specific requirements set them apart. Their Adapto Goods-to-Person (GTP) solution and HDS case buffer technology was tailored specifically to our needs, setting our supply chain up for years to come.”
Michael Masulans, Director, General Manager Finance & Administration, ASICS Oceania
After two and a half years, the project was completed without disrupting customer service. ASICS maintained full operational capacity throughout the build, compressing roughly one-third of their warehouse operations while construction proceeded. This required coordination between multiple contractors, electricians, and fire safety specialists in the live warehouse environment.
ASICS and ThreeSixty established meticulous advance planning processes, including detailed 3D design workshops conducted across different time zones to ensure all parties clearly understood equipment placement and integration requirements.
“We put aside nearly three or four months for end-to-end testing, and it’s one of the best go-lives I’ve seen from a software perspective. ASICS leveraged ThreeSixty and Vanderlande’s strengths to achieve the goal of not disrupting customer service levels while processing live orders, product testing, and hundreds of test scripts. Software issues can plague these kinds of automation projects, but we had the right WMS partner, the right IT project managers, and the right IT resources to ensure the software integration was seamless,” said Derek Tan, Executive Director ThreeSixty. When we were presented with structural weight limitations and throughput requirements, our engineering team worked closely with ASICS to find the right solution. The pivot from mini-load to High Dynamic Storage technology not only resolved the immediate challenges but delivered performance that exceeded the original specifications. This project shows how close collaboration and flexibility can turn constraints into advantages.”
Roald De Groot, Sales Director Vanderlande
The Result
The Kakushin project has positioned ASICS for future expansion, with built-in capacity for additional pick stations, pack stations, and potential AGV capability. The project provides a scalable foundation supporting operations through 2030 and beyond, while delivering environmental benefits through reduced packaging waste and more efficient container loading processes.
For more details please read the ASICS Case Study.
