Distribution Facility Expansion (Notes)

6 Months Ended

Aug. 01, 2015

Distribution Facility Expansion [Abstract]

Property, Plant and Equipment, Schedule of Significant Acquisitions and Disposals [Table Text Block]

Distribution Facility Expansion, Consolidation & Technology Upgrade

During fiscal 2014, we began a significant operational expansion initiative with respect to overall warehousing capacity and new equipment and system technology upgrades at our Bowling Green, Kentucky distribution facility. During the first quarter of fiscal 2015 the new building was substantially completed and expanded our 262,000 square foot facility to an approximately 600,000 square foot facility. The physical building expansion portion of the initiative was completed in the first half of fiscal 2015 and the Company moved out of its leased satellite warehouse space during the second quarter of fiscal 2015. The updated facilities and technology upgrade will include a new high-speed parcel shipping and item sortation system coupled with a new warehouse management system to support our increased level of shipments and units and a new call center facility to better serve our customers. The new sortation and warehouse management systems are expected to be phased into production through the first quarter of fiscal 2016, which is approximately two quarters later than originally anticipated. Total cost of the physical building expansion, new sortation equipment and call center facility is estimated to be approximately $25 million and is being financed with our expanded PNC revolving line of credit and a $15 million PNC term loan. As of August 1, 2015, we have expended approximately $21 million in cash relating to the Bowling Green expansion initiative with additional cash commitments of approximately $4 million expected to be made over the next three quarters and primarily funded from the Credit Facility.

As a result of our distribution facility consolidation and technology upgrade initiative, the Company incurred approximately $972,000 in incremental expenses during the second quarter of fiscal 2015, relating primarily to increased labor, inventory and other warehousing transportation costs, training costs and increased equipment rental costs associated with: the move into the new expanded warehouse building, the move out of previously leased warehouse space and the preparation of our expanded facility for the new high-speed parcel shipping and item sortation system and upgraded warehouse management system.