Overview
When equipment issues began compromising sortation accuracy at a major distribution center, the facility brought in Fidus Global to get ahead of potential operational disruptions. Within 24 hours, a Fidus technician was on-site conducting a full system audit, identifying root causes, and completing critical repairs to stabilize performance. Just as importantly, our team worked alongside the facility's maintenance staff, transferring knowledge and strengthening their ability to handle future issues with confidence.
Results At A Glance
The Challenge
A week of lost production had already occurred after a crash on the SL2 sorter. The incident stemmed from a slat not being reinstalled properly after a broken shoe pin, and while mechanical repairs were made quickly, the facilities internal team lacked the experience to bring the system back online. This gap left the operation under mounting pressure to restore throughput and stability before performance issues escalated further.
The Solution
Fidus dispatched a technician immediately after receiving a call, arriving on-site the following morning to perform a full system audit. After an initial walkthrough with the facility team, the technician conducted physical inspections, component testing and divert-by-divert checks, documenting faults such as broken shoe caps, damaged slats, unseated snap rings, and an improperly mounted flipper preventing full divert engagement.
By collaborating closely with the site team, Fidus prioritized critical repairs and created a follow-up plan for remaining part replacements.
Implementation
During the visit, the Fidus tech replaced seven broken shoe caps, replaced a damaged slat, secured sensor covers, and corrected the flipper installation to restore proper divert function, all without interrupting operations. A replacement divert rail was logged for follow-up, and comprehensive documentation was provided to guide next steps.
A final inspection was completed ahead of shift startup on day three, confirming restored performance and stability.
Conclusion:
In under three days, Fidus Global helped a high-volume distribution center regain stability, complete key repairs, and restore sorter performance without placing extra strain on internal teams or disrupting outbound flow.
For maintenance leaders stretched thin and operations managers juggling daily pressure, this kind of hands-on, solutions-first support makes the difference. Fidus doesn't just restore equipment, we transfer knowledge, strengthen technical skills, and give teams the confidence to troubleshoot and resolve future issues on their own. By combining expert problem-solving with customer empowerment, we ensure operations run smoothly today while equipping teams to be more resilient tomorrow.