Sunrun is the largest dedicated residential solar company in the United States with a mission to create a planet run by the sun. Since establishing the solar as a service model in 2007, Sunrun continues to lead the industry in providing clean energy to homeowners with little to no upfront cost and at a savings to traditional electricity. The company designs, installs, finances, insures, monitors and maintains the solar panels on a homeowner’s roof, while families receive predictable pricing for 20 years or more.
With a rapidly increasing consumer demand for home solar solutions, Sunrun turned to Conveyor & Storage Solutions to execute a large-scale “brick and mortar” facility expansion spanning 40+ warehouse locations across 14 states nationwide. Sunrun’s primary objective was to implement an effective nationwide delivery and installation system that minimized costs while achieving installation projections with sustained year-over-year growth.
Conveyor & Storage Solutions partnered with Sunrun to identify nationwide warehouse facilities with optimal space utilization. C&SS provided strategic consultation and analysis to support Sunrun’s lease negotiations by evaluating storage capacity and operation capability of unoccupied potential warehouse buildings in each new market. C&SS examined building details including overhead clearances, sprinkler system design, fire access door and egress requirements, disability-related accessibility requirements, and any other potential challenges that would lead to delayed tenant occupancy or incur additional costs.
Conveyor & Storage Solutions collaborated with Sunrun to custom design-build facility locations to maximize efficiency, productivity and profitability. The lead time for a custom system typically ranges from eight to 14 weeks. In most cases, Sunrun required delivery and installation in under four weeks. C&SS provided innovative design-build solutions and successfully achieved aggressive delivery and installation lead times to meet Sunrun’s objectives.
Conveyor & Storage Solutions provided strategic space planning and storage rack design to maximize Sunrun’s storage rack capacity, improve operational efficiency and assure code compliance. The C&SS in-house design team specialists evaluated and identified maximum storage rack capacity and operation capabilities for Sunrun using computer aided drafting (CAD) software. C&SS integrated a variety of material handling systems including high-bay pallet racks, cantilever racks, dynamic carton flow racks, wire mesh partition security cages and industrial steel shelving. With a strong commitment to safety and compliance, C&SS assured that all design and space planning solutions adhered to requirements and regulations for building codes, fire protection for high piled storage and seismic engineering.
Conveyor & Storage Solutions dramatically reduced installation lead time with an innovative approach to stocking rack inventory. C&SS leveraged long-term relationships with a coast-to-coast network of leading national manufacturers, suppliers, and partners to provide a cost-efficient solution for stocking rack inventory materials. As a direct result of this strategic inventory storage solution, C&SS successfully facilitated Sunrun’s ambitious delivery and installation projections while saving an average of 10 weeks of lead time per warehouse.
Conveyor & Storage Solutions delivered a state-of-the-art nationwide distribution operation that successfully supported Sunrun in achieving long-term growth objectives, reducing costs, and delivering a high quality customer experience. An overview of positive outcomes includes:
• 40+ warehouse expansion locations across 14 states nationwide
• Achieved approximately 400,000 square feet of warehouse space expansion
• Saved 10 weeks of lead time per facility as a direct result of stocking inventory solution
• Averaged three-day installation time for all brick and mortar building locations
• Supported Sunrun in achieving over monumental market growth in 36 months
Throughout this project, Conveyor & Storage Solutions demonstrated a commitment to customer-driven solutions with strong service delivery in the following areas:
• Anticipation of Customer Needs
• Rapid Response
• Expert Consultation and Building Analysis
• Strategic Partnership to Support Long-Term Growth