CDW Support Case Study: Predictive and Proactive Maintenance Strategy

EXECUTIVE SUMMARY

Following the successful delivery of the strategy and fit-out phases of the CDW automation project, Milestone was awarded the long-term support contract to ensure continuous improvement, maximum uptime, and sustained operational efficiency.

This engagement includes 24/7 software and hardware support, resident maintenance technicians, and remote diagnostics, all integrated into a single, state-of-the-art maintenance management platform powered by Milestone’s MMS.

By leveraging a predictive and proactive maintenance strategy, CDW has benefited from:

99% SYSTEM UPTIME

Through predictive & proactive maintenance strategies

24/7 SUPPORT

Minimising downtime and increased troubleshooting speed

ONSITE ENGINEERS

Onsite engineers trained to optimise system performance

INTRODUCTION

CDW UK, is a leading technology solutions provider requiring an end-to-end logistics transformation to triple warehouse throughput and improve operational efficiency.

After successfully designing and implementing their automated warehouse, the next step was to ensure long-term reliability and maximise the return on their investment.

With a complex setup including a 16,000-tote ASRS, extensive conveyor networks, AMRs, Pick Towers, and Volumising systems, CDW needed a dedicated maintenance partner capable of maintaining peak performance with minimal downtime.

Milestone’s turnkey approach – combining strategy, fit out, and support – ensured a seamless transition to a fully optimised operation.

PROBLEM STATEMENT

Post-go-live, CDW faced several challenges:

SOLUTION DESIGN

Resident Engineering Team
  • Three dedicated engineers permanently stationed at CDW.
  • Proactive daily system inspections, preventive maintenance, and real-time troubleshooting.
  • On-demand response for emergency repairs.
24/7 Remote Support and Monitoring
  • Software and controls engineers available around the clock for PLC and automation-related issues.
  • Automated fault alerting system for rapid response.
  • Secure remote access to PLCs and automation control systems via VPN.
Milestone Maintenance System (MMS)
  • QR-coded asset management for easy tracking and maintenance history logging.
  • Automated fault ticketing system for real-time reporting.
  • Live dashboards providing availability tracking, maintenance KPIs, and historical analysis.

IMPLEMENTATION PROCESS

Phase 1: System Audit and Integration

  • Comprehensive site audit of all automation, mechanical, and electrical systems.
  • Integration of existing assets into Milestone’s MMS, including:
    • 16,000-tote ASRS system
    • AGVs and AMRs for transport and picking
    • 500 m of conveyors
    • VNA racking and semi-automated trucks
  • Defined service-level agreements (SLAs) with response times and escalation procedures.

You can read more about the automation integration stage of the project here.

Phase 2: Engineer Training and Handover

• Resident engineers underwent manufacturer-specific training (Hai Robotics, AMRs, PLC systems).
• Knowledge transfer sessions with CDW’s internal logistics team.
• Implementation of a preventive maintenance schedule aligned with peak demand cycles.

Phase 3: 24/7 Support Activation

• Milestone’s helpdesk and remote support centre went live with dedicated escalation paths.
• Live MMS dashboards enabled real-time issue tracking and asset monitoring.
• Continuous improvement initiatives were introduced to enhance system efficiency over time.

CHALLENGES & SOLUTIONS​

Challenges

High Variability in Workloads

Warehouse throughput fluctuated daily, creating prioritisation challenges.

Training and Knowledge Gaps

CDW’s in-house team lacked experience with integrated automation.

Fault Isolation and Root Cause Analysis

Complex integration meant faults could originate from multiple sources.

Solutions

Focus on Critical Systems

MMS real-time workload balancing ensured engineers focused on critical systems.

Customised Training Programmes

Customised training programmes enabled CDW staff to handle routine troubleshooting.

Remote Diagnostics

Remote diagnostics and MMS fault history tracking allowed quicker root cause identification.

KEY LEARNINGS & RECOMMENDATIONS

PLAN AUTOMATION & SUPPORT TOGETHER
Turnkey approaches ensure systems are designed for maintainability.
PROACTIVE MAINTENANCE COSTS
Predictive strategies prevent costly breakdowns.
RESIDENT ENGINEERING TEAMS IMPROVE PERFORMANCE
Dedicated engineers who understand both business and technology are invaluable.
REAL-TIME MONITORING ENABLES RAPID DECISION MAKING
Live system visibility supports data-driven continuous improvement.

CONCLUSION

CDW’s journey from strategy to implementation to ongoing support has created a highly efficient, resilient, and future-proof logistics operation.

Milestone’s end-to-end support model, including resident engineers, remote diagnostics, and data-driven maintenance planning, ensures that CDW’s automation investment continues to deliver long-term value.
By integrating cutting-edge automation with best-in-class support, CDW has achieved:

• Unprecedented throughput and efficiency
• Minimal downtime with real-time fault management
• Full visibility over system performance
• Scalable, future-proof automation for continued growth

CDW’s success demonstrates the value of a single, trusted partner for automation, integration, and support. Milestone’s combined strategy, fit-out, and support approach ensures customers receive not just a system, but a high-performance logistics solution that evolves with their business.

If you’re looking for a support solution for your warehouse, or you’re just looking for ways to improve efficiency in your material handling operations, you can see more of our case studies here, or you can get in touch with us with any questions about this project or our services.

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