Spartan Logistics Case Studies

Delaware, Ohio Location

Executive Summary

Spartan Logistics partnered with a national consumer goods manufacturer to support the strategic relocation of warehouse operations closer to the partner’s manufacturing plant in Delaware, Ohio. After six years of a successful partnership at Spartan’s Lockbourne facility, the customer sought to reduce transportation costs and improve operational efficiency by leasing a warehouse near the plant. Spartan was selected to operate the new Delaware facility under a cost-plus model, leveraging its operational expertise while navigating the challenges of a customer-led startup.

Client Background

Client: Long-standing manufacturing partner
Industry: Personal care products
Partnership Length: 6+ years

Spartan Logistics has worked closely with this customer for over six years, receiving products directly from the manufacturing plant and managing storage and distribution to regional distribution centers. The long-standing partnership was built on trust, operational consistency, and service reliability.

The Challenge

The manufacturer identified an opportunity to significantly reduce transportation costs by relocating warehouse operations closer to their manufacturing plant in Delaware, Ohio. While Spartan proposed building or purchasing a facility to meet these needs, the partner ultimately chose to lease a warehouse and lead much of the startup process internally.

Key challenges included:

• Transitioning operations from the Lockbourne facility to a new Delaware location
• Limited early involvement from Spartan in warehouse setup and infrastructure planning
• Delays typical of a startup environment
• Lack of system scanning functionality before the official go-live date

Goals & Objectives

• Reduce transportation costs by positioning inventory closer to the plant
• Successfully launch a new warehouse operation with minimal service disruption
• Maintain service levels during high-volume live load activity
• Seamlessly transition systems, inventory, and labor to the new facility

The Solution

Spartan Logistics agreed to operate the Delaware facility under a cost-plus structure, providing operational leadership, labor management, and system expertise once the warehouse went live. Throughout the startup phase, Spartan’s IT and operations teams remained available to support the manufacturer, offering guidance and problem-solving assistance as needed.

A key component of the solution was onboarding several former partners’ employees into Spartan roles. Their familiarity with the product and systems proved invaluable during the transition.

Implementation

The move from Lockbourne to Delaware required close coordination and adaptability. Before go-live, inventory was manually managed because items could not be scanned to locations. Teams manually entered LPNs into bin locations to keep operations moving.

Once systems were live:

• Supervisors ensured teams stayed on task and outbound loads remained on schedule
• Customer Service Representatives (CSRs) managed a high volume of live loads while preparing documentation for upcoming shipments
• An inventory specialist verified that all products were properly scanned and assigned to correct locations once scanning became available

Despite early limitations, collaboration between Spartan teams and former partners’ employees helped stabilize operations quickly.

Results & Outcomes

• Successful go-live at the Delaware, Ohio facility
• Reduced transportation distance and associated costs
• Minimal disruption to daily shipping volumes
• Strong operational performance during a complex startup phase
• Reinforced long-term partnership between Spartan Logistics and its partner

Key Takeaways

• Strong partnerships enable flexibility during complex transitions
• Experienced CSRs and supervisors are critical during live-load, high-volume operations
• Cross-company knowledge transfer can significantly reduce startup risk
• Spartan’s operational expertise adds value even in customer-led warehouse startups

Learn more about Spartan Logistics’ Delaware, Ohio facility at spartanlogistics.com.