Custom Warehouse System Layout and Design That Meets Your Operation's Needs

In a world where no two fulfillment operations are alike, standard solutions can’t always address the most challenging or unique business requirements. That’s why we offer Engineered Solutions: a team of material handling, software and control engineers dedicated to creating custom solutions for your biggest challenges.

Engineered Solutions allows you to put the industry’s most experienced and knowledgeable experts to work on your specific fulfillment problem, scenario or upgrade — before you make a big investment in equipment or technology. 

Whether you’re trying to meet peak season demand levels, adapt to new product profiles, achieve new levels of overall equipment effectiveness, or meet changing customer requirements, Engineered Solutions provides a wide range of professional services to help you streamline the change management process. This multidisciplinary approach offers you an efficient resource for assessing your business requirements and developing custom, cost-effective solutions to increase the effectiveness of your fulfillment operations.


Assessments are critical for any successful lifecycle management program. Regardless of system maturity, they help companies proactively evaluate overall system performance and health risks to prevent issues and preserve system uptime. Honeywell utilizes an expert assessment team who deploys a field-tested approach to gauge operational performance and conditions against established benchmarks. 

Every assessment includes the following services and deliverables:

  • Expert evaluation of major components and an overview report prior to leaving the site
  • Follow-up, detailed report with a summary of findings, risk level for each major component and recommendations for improvement
  • Inspections certificate containing photos and measurement data (when applicable)
  • Recommendations for upgrades or product enhancements
  • Parts quote for replacement components
  • Discussions to ensure clear understanding of findings and recommendations

Productivity Assessments

We provide enhanced operational visibility and access to key productivity metrics. You can leverage this intelligence to:

  • Gain data-driven, operational insights that can be implemented in real time during production
  • Reduce unplanned events to meet production targets and avoid costly heroics
  • Maximize productivity by balancing the entire supply chain within the distribution center
  • Lower operating costs, such as energy consumption and transportation expenditures
  • Improve labor optimization and retention

Reliability Assessments

Reliability assessments evaluate equipment’s operational condition and functionality levels. These can be used to:

  • Address a variety of technologies, such as line and loop sorters, palletizers, conveyors and pick-to-light systems
  • Examine critical internal components in each equipment category
  • Perform root cause analysis and repair prioritization

Safety Assessments

Safety assessments evaluate component conditions, plan for technological obsolescence, and ensure safe work environments, including:

  • Leveraging thermographic imaging, current and voltage draw to identify potential electrical failure
  • Identifying obsolete components
  • Backup and recovery verification of critical components
  • Asset adherence to the latest OSHA and ANSI safety regulations

Efficiency Assessments

Efficiency assessments review the effectiveness of maintenance programs and seek to optimize how well operators interface with material handling equipment.

  • Analysis of maintenance practices and recommendations for best-in-class asset management
  • Review effectiveness of maintenance automation tools: computerized maintenance management systems (CMMS) and enterprise asset management (EAM) systems
  • Assess system performance and detail steps needed to return to its original, as-designed condition while ensuring optimal system wear
  • Review and observe system operations and product flow
  • Identify system constraints versus operational expectations
  • Observation of equipment operator behaviors and performance

Changes to Business Operations

As you confront the challenges of modernizing legacy control systems, Engineered Solutions provides obsolescence planning for critical control system components. These projects help you reconcile obsolescence while providing modern enhancements to deliver increased system capacity, flexibility and longevity. Modifications and upgrades include the following services:

Controls and Software

  • Complete control platform upgrade or replacement
  • Mid-life system technology refreshes
  • PLC and HMI replacement
  • Obsolescence- or performance-driven variable frequency and servo drive replacements
  • Obsolescence- or performance-driven scanner and vision upgrades

Mechanical and Electrical

  • Line, tilt-tray and cross-belt sorter rebuilds and upgrades for maximum efficiency, uptime and accuracy
  • ZoneFlex® Advanced increases throughput up to 45%, improves product handling, and reduces side-by-sides on existing conveyor lines
  • Palletizer upgrades, retrofits and repurposing to enhance operation, productivity, safety and support product and packaging changes
  • Product enhancement updates (PEUs) for scalable, continuous improvement

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