How a Fortune 500 Retailer Saved $4.4M With a Smart Recontrol Strategy

No rip-and-replace. Just open architecture, smart upgrades, and measurable results.

The Numbers Speak for Themselves

Overview

A major US retailer was operating with aging conveyer systems, rigid and proprietary OEM software, and no way to troubleshoot or adapt without waiting on the manufacturer. Breakdowns slowed throughput, added labor costs, and left operations in the dark.

Fidus Global stepped in with a recontrol strategy using Pontem, replacing black-box software with open, PLC-based logic and adding multi-wave management to accelerate order flow. The result: a 13% jump in throughput, $4.4M in annual savings, and a full ROI in just over a year - all without a full system rip-and-replace.

The Problem: Aging Tech and Hidden Costs

The customer's warehouse was nearing end-of-life, marked by:

   Frequent breakdowns disrupting fulfillment

 OEM-locked software with limiting in-house visibility

  Rising labor costs and support delays

 No scalability without major infrastructure overhaul

The Solution: Smart Recontrol with Pontem

A Right-Sized Modernization Plan

Fidus Global began with a full warehouse assessment, designing a targeted recontrol strategy to restore operational control — without unnecessary capital spend.

Open-Architecture WCS with Pontem

At the core of the solution was Pontem, Fidus' open-architecture warehouse control software. By replacing the OEM’s closed system with PLC-based logic, the internal team could finally troubleshoot, adjust, and optimize performance independently.

Multi-Wave Order Management

To accelerate throughput without overbuilding, Fidus implemented multi-wave management — enabling the warehouse to process several order batches simultaneously. This streamlined fulfillment and reduced labor during peak volumes.

Selective Hardware Upgrades

Rather than ripping out aging systems entirely, Fidus preserved the core infrastructure and replaced only key components — including sensors, actuators, and drives. This balanced approach extended equipment life, improved uptime, and avoided a full facility shutdown.

Implementation & Results

Zero Downtime Transition
The upgrades were completed with minimal downtime and no disruption to ongoing operations. Once Pontem and multi-wave management were validated, the system moved into production quickly delivering measurable improvements across performance, cost, and control.

Conclusion

By modernizing only what was necessary and replacing rigid OEM systems with Pontem's open architecture, this Fortune 500 retailer unlocked significant operational and financial gains - without the disruption of a full system overhaul. With increased throughput, real-time visibility, and the freedom to scale on their terms, the business is now positioned for smarter, more resilient growth.