Fortune 500 Retailer Migrates Legacy WMS to Enable Faster, Scalable Fulfillment Across DCs
Fortune 500 US apparel and lifestyle retailer operating a multi-node distribution network across North America
The challenge
The client was running a 20+ year-old legacy WMS that lacked scalability, real-time visibility, and flexibility to support growing omnichannel demand. Warehouse operations were heavily manual, leading to slower fulfillment cycles, limited inventory accuracy, and increased operational costs across distribution centers.
What Everest delivered
Everest led the end-to-end migration from a legacy AS/400-based WMS to a modern, cloud-enabled warehouse management platform (Manhattan Active WMS), deployed across 5 distribution centers and 280+ stores. The engagement covered solution design, system configuration, integration with upstream and downstream systems, data migration, testing, and go-live support delivered by a cross-functional team of 30 consultants across supply chain, data engineering, and quality engineering.
Solution components
- End-to-end WMS implementation (Manhattan Active)
- Real-time inventory visibility across DCs and stores
- Automated picking, packing, and replenishment workflows
- Integration with OMS, transportation, and store systems
- Performance testing and quality assurance for high-volume operations
Business outcomes
- 38% reduction in order-to-ship time across distribution centers
- 31% improvement in warehouse labor productivity
- 99.6% inventory accuracy achieved at go-live
- 24% reduction in fulfillment errors and returns
- $4.3M annual operational cost savings
Everest helped us successfully transition from a legacy system to a modern WMS without disrupting operations. The improvements in speed, accuracy, and scalability have been significant across our network.