ASICS partners with ThreeSixty for warehouse automation project in Sydney

ASICS has successfully transformed its Australian warehouse operations at its Marsden Park facility in Sydney, achieving significant productivity improvements through the implementation of advanced automation technology.

Looking to adapt its business operations as it shifted from large wholesale shipments to smaller consumer and e-commerce orders, ASICS required changes to its warehousing operations to efficiently process the growing volume of multi-item orders that characterise modern retail fulfilment.

The company teamed up with automation specialist Vanderlande to automate key processes and implement modern systems. The project, named “Kakushin” – a Japanese term meaning innovative transformation – was delivered in partnership with supply chain consultancy ThreeSixty.

The project was completed after two and a half years without disrupting customer service or business operations. Michael Masulans, Director and General Manager, Finance & Administration at ASICS, said: “At our NSW Marsden Park facility, the new automation system has significantly increased processing capacity and efficiency, with room for future growth.”

The Kakushin project has positioned ASICS for future expansion, with built-in capacity for additional pick stations, pack stations and the potential use of autonomous vehicles. The project provides a scalable foundation to support operations through 2030 and beyond, while delivering environmental benefits through reduced packaging waste and more efficient container-loading processes.

The collaboration

Throughout the implementation, ASICS maintained full operational capacity, confining roughly one-third of its warehouse operations while construction proceeded. This required coordination between multiple contractors, electricians and fire safety specialists in the live warehouse environment.

“Strong collaboration played a huge role in the success of this project,” said Masulans. “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 willingness to adapt its solutions to our specific requirements set it apart.”

To ensure the project remained on track, ASICS and ThreeSixty established a detailed planning process, including 3D design workshops conducted across different time zones to ensure all parties clearly understood equipment placement and integration requirements.

According to Derek Tan, Executive Director at ThreeSixty, another key success factor was the strong focus on ensuring a seamless go-live. “Software issues can plague these kinds of automation projects, but ASICS had the right WMS partner, the right IT project managers and the right IT resources to ensure the software integration was seamless.”

“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.”

High Dynamic Storage

Along the transformation journey, ASICS faced significant technical challenges, including fire safety issues and the discovery that the warehouse slab was not built to automation specifications. This required innovative engineering solutions, ultimately leading to the adoption of High Dynamic Storage (HDS) 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 also delivered superior performance, achieving more movements per hour than required. The HDS buffer system addresses the site’s operational constraints caused by limited dock capacity, providing essential space and sequencing for palletising stations and dispatch operations.

“When we were presented with structural weight limitations and throughput requirements, our engineering team worked closely with ASICS to find the right solution,” said Roald De Groot, Sales Director at Vanderlande. “The pivot from mini-load to High Dynamic Storage technology not only resolved the immediate challenges but delivered performance that exceeded the original specifications.”

In the spotlight

Since going live, the Sydney warehouse automation project has attracted industry recognition for its results and delivery. At the 2025 ASCLA Awards in Melbourne Town Hall late last year, the project won the Supply Chain Management Award.