Critical Project Delivery – Case Studies

Turning complexity into capacity through strategic project leadership

Click below to check the Case Studies

Client / Sector

Retail Distribution

Scope & Role
  • 1.6M sq ft greenfield distribution center in the Midwest
  • $125M capital budget
  • Automation-rich design - AS/RS, goods-to-person, robotics, high-density racking
  • Don Cooper served as Project Lead, responsible for construction, material handling equipment, and automation
Challenges
  • Aggressive timeline for occupancy and go-live
  • Integration of multiple automation vendors drove dense, complex building design
  • Budget control under Covid-19 supply disruptions
Approach / Solution
  • Directed a phased project plan with clear critical path controls
  • Met with labor unions' leadership to garner support for a constructive partnership
  • Coordinated automation, construction, and permitting streams to stay on schedule
  • Performed multiple structural design reviews to maintain alignment on capacity
  • Maintained tight cost controls and vendor accountability throughout design and build
Outcome / Impact
  • Completed one month ahead of schedule
  • Delivered 2% under budget on a $125M project
  • Facility launched with full automation and throughput capacity
Turning complexity into capacity - this project delivered a flagship distribution center that sets the benchmark for a major retailer's future growth.

Client / Sector

Confidential - California Multi-shift Distribution Center

Scope & Role
  • Installation/Retrofit of HVAC system in a 5x24 operating distribution center
  • $16M capital budget
  • Don Cooper served as Project Lead, directing strategy, design, and phased execution
Challenges
  • Live facility with no option for contractor interior access Monday-Friday
  • Rising employee turnover tied to extreme heat conditions
  • State regulations tightening heat exposure regulations required action
Approach / Solution
  • Structured work phases: exterior work on weekdays, interior installations completed on weekends
  • Evaluated the potential HVAC designs to include not only cost but especially time to completion
  • Selected air rotation units (ARUs) over rooftop units (RTUs) to achieve a better schedule and cost
  • Coordinated closely with building inspectors to ensure full compliance with energy regulations
  • Maintained 24/7 service levels while construction was underway
Outcome / Impact
  • Completed two months ahead of schedule
  • Delivered 6% under budget on a $16M project
  • Achieved compliance with new heat exposure regulations
  • Improved employee retention and working conditions
Compliance and performance can go hand in hand - turning a regulatory burden into a quality-of-workspace advantage.

Client / Sector

Distribution Center Infrastructure (South Carolina)

Scope & Role
  • $7M infrastructure project, partially county-funded but primarily led and financed by Harbor Freight Tools
  • Three-year duration, including county approvals and construction delivery
  • Scope included highway widening, new traffic light, roadway demolition, connector roads, and improved turning radius
  • Don Cooper served as Project Liaison and Design Contributor, aligning county, corporate, and site leadership with contractors and engineers
Challenges
  • Site congestion plagued workforce and management for over two years, with long egress delays for 1,000+ associates
  • Required coordination between county government, engineering firms, contractors, and corporate leadership
  • Balancing cost-sharing and funding approvals with county and company stakeholders
Approach / Solution
  • Assisted in roadway design and overall traffic flow planning
  • Secured funding support from both Harbor Freight and county resources
  • Acted as liaison across stakeholders: county, corporate, site leadership, engineers, and contractors
  • Oversaw design reviews and ensured alignment with workforce and construction needs
  • Supported demolition, road extension, connector design, and improved traffic flow into the DC campus
Outcome / Impact
  • Completed successfully with widened South Carolina Hwy. 34 (from 3 lanes to 5 lanes)
  • New traffic light on Hwy. 34 installed
  • Connector and extension roads completed, improving access to employee parking and logistics flows
  • Traffic congestion eliminated, dramatically improving safety and reducing wait times for 1,000 associates
  • Strong example of public–private partnership that addressed workforce needs and regional infrastructure challenges
This project turned years of daily frustration into reliable access and safe traffic flow — strengthening both operations and workforce satisfaction.