Fashion & ApparelHigh-throughputRetail

INTRODUCTION 

Facing rapid growth and scalability needs, Helly Hansen, the leading manufacturer of sportswear and workwear for rugged outdoor environments, partnered with Element Logic to transform its Sumner, WA, distribution center with the AutoStore automated storage and retrieval system (ASRS). This strategic move addressed growth and efficiency challenges and streamlined operations, boosting efficiency and customer satisfaction—a key milestone in Helly Hansen’s quest for operational excellence. 

Helly Hansen & Element Logic Automate DC with AutoStore 

THE CHALLENGE 

Helly Hansen’s rapid U.S. expansion highlighted critical scalability and efficiency challenges. The brand sought a scalable solution to enhance distribution and exceed customer expectations. A partner with global reach, a strong U.S. presence, 24/7 support, and top-tier software became essential for navigating these complexities and achieving a seamless, efficient operational upgrade. 

Scaling Up in the Competitive U.S. Market 

THE SOLUTION 

A Seamless Automation Transition 

Optimizing Operations with AutoStore ASRS 

Helly Hansen partnered with Element Logic to overhaul its distribution operations using the AutoStore automated storage and retrieval system (ASRS). This implementation, featuring 50,000 bins, 36 robots, and 10 carousel ports, marked a shift towards unparalleled operational efficiency. The transition from manual, labor-intensive processes to an automated, efficient system addressed the critical challenge of Helly Hansen’s rapid growth and the need for adaptable warehouse space. 

eManager, Industry-Leading Warehouse Management Software (WCS)  

AutoStore, augmented by  Element Logic’s WCS system, eManager, redefined Helly Hansen’s order fulfillment approach. The AutoStore system not only simplifies the handling of various order types—including direct-to-consumer, e-commerce, and complex wholesale—but also integrates picking, packing, and shipping into a seamless, unified operation.  

THE IMPACT 

The Transformative Impact of AutoStore 

The deployment of AutoStore by Element Logic transformed Helly Hansen’s operations. With a more efficient system, e-commerce orders that were previously taking 2-3 days can now be completed in just half a day, enhancing customer satisfaction through quicker deliveries. Furthermore, the shift to automation improved employee well-being by reducing the physical demands of warehouse work and overtime needs during peak season. AutoStore’s modular design ensures Helly Hansen’s operation remains agile and scalable, aligning perfectly with its growth trajectory and reinforcing its commitment to operational excellence.  

PARTNER SELECTION 

Choosing Element Logic 

Helly Hansen prioritized finding a partner that could elevate its distribution efficiency.  Element Logic emerged as the optimal choice due to its global infrastructure, cutting-edge technology, and robust support.  Element Logic’s 24/7 support, factory-trained technicians, and superior warehouse management software were critical to this selection, aligning perfectly with Helly Hansen’s need for a partner to support their growth in the U.S. market. 

“The proven track record of Element Logic in exceeding Helly Hansen’s expectations in Europe established a deep trust in their capabilities,”  

– Brian Crowle, Account Executive at Element Logic.  

THE RESULTS 

 Element Logic’s implementation of the AutoStore solution has been a resounding success. Helly Hansen experienced a significant transformation in its distribution operations, marked by enhanced efficiency, scalability, and customer satisfaction.  

Success with AutoStore Solution by Element Logic 

Space Optimization 

Increased storage capacity in the existing footprint 

Speed and Efficiency 

Reduced order fulfillment times from 2-3 days to half a day 

Reliability 

Achieved exceptional uptime with minimal disruptions 

Flexibility & Scalability 

Enabled easy system expansion to match growth 

Operational Excellence 

Reduced operational costs and enhanced employee well-being 

The post Helly Hansen Revolutionizes Distribution Center with Element Logic Partnership and Adoption of AutoStore appeared first on Element Logic US.

Fashion & Apparel

Key Highlights 

The Element Logic Solution for Stage Stores 

CONSULTANCY APPROACH: As part of Element Logic’s consulting approach, we analyzed the issues and limitations from which Stage Stores suffered– ranging from limited manual processing capacity to lack of space within the DC– and provided a solution that tackled those problems and increased accuracy. 

AUTOMATED SOLUTION: Implemented Joey Pouch Sorter. 

ENHANCED OPERATION: The solution increased space efficiency, accuracy, speed, and overall operational productivity. 

THE CHALLENGE 

Stage Stores fulfilled E-Commerce orders utilizing a strategy incorporating a limited number of stores as well as their Distribution Centers– one Distribution Center was designated as the primary E-Commerce fulfillment location. As their E-Commerce continued to grow, the pattern they were seeing was clear: a higher number of orders with a low number of items per order, combined with a rapid-growing SKU count. 

The manual fulfillment process utilized by the primary fulfillment location was not going to be able to meet the demands of the next peak season. It was clear that a new solution had to be delivered prior to peak, which was only nine months away. 

Stage Stores’ small store footprints and their fast-growing E-Commerce SKU count made things more difficult. Stage knew that adding more stores to the fulfillment strategy would increase the likelihood of generating multiple shipments to a customer and increase the shipping cost. They also knew that maintaining the operation centralized posed numerous challenges of its own. 

In addition to all of this, Stage was beginning to suffer from a limited footprint in their DC. With only manual Put Wall systems present, no physical space to expand, and a limited timeline; Stage Stores needed an innovative solution that would allow them to stay their course and fulfill E-Commerce orders from their DC. 

THE SOLUTION 

Element Logic provided Stage Stores with a state-of-the-art solution that went above and beyond solving the difficulties they were facing. The Joey Pouch Sorter went into the 436,000 sq. ft. –already filled DC—only needing space for induction, which worked with the limited footprint by using space that could not be taken advantage of before. 

“One of the reasons the Pouch system fit us so well, is that we didn’t have to add any floor space, we were just able to add it to our existing facility,” James Deal, Director of E-Commerce Fulfillment at Stage Stores, said. “And people learned the system really quickly, because of its ease of use and training.” 

In addition to having an intuitive system that helped shorten the learning curve, the productivity has also been positively affected. 

“We were processing 1,000 items per hour with our put wall previously.” Deal added. “Now, with Joey, we were able to double our capacity and process about 2,400 items an hour.” 

THE SYSTEM 

The system works like this: 
A picker walks around the DC with a cart and picks items into big bins. Once the picker fills these bins, he or she will bring the items into the system by scanning each item (in any order) and putting it into a pouch. At this point, the process is fully automatic. 

 
As each item gets scanned, the item is married (linked) to the pouch in which it’s placed. One by one, each pouch whisks their item into the ceiling. Once in the air, the pouches are taken to the staging area (above a cafeteria), where via sophisticated algorithms, the system places the pouches into ordered sequence. Once the pouches are assembled in ordered sequence, they circulate above until packing becomes available. As packing stations free up to receive more orders, the system releases the pouches in ordered sequence out to them. 

 
At Stage Stores, there are different types of pack stations that can handle different order volumes, so the system preemptively considers how much the volume for each order will be and sends it to the corresponding packing station. The items are either packed automatically or by a person at a packing station and then shipped. 

ABOUT Stage Stores 

Stage Stores Inc. brings moderately priced, nationally- recognized brand name and private label apparel accessories, cosmetics and footwear for the entire family across 40 states. 

Stage Stores operates approximately 797 stores under the “Bealls,” “Palais Royal,” “Peebles,” “Goody’s,” and “Stage,” trade names and they are supported by three Distribution Centers. 

The post Stage Stores Case Study appeared first on Element Logic US.

Key Highlights 

The ELEMENT LOGIC Solution for Saramax 

CONSULTANCY APPROACH: As part of Element Logic’s consulting approach, we analyzed the SKU and order details and provided location mapping for the existing and new pick modules–balancing the work evenly between pick zones and providing new SKU order details. 

AUTOMATED SOLUTION: Implemented a Pick-to-Light system and MDR spiral incline conveyors. 

ENHANCED OPERATION: The solution increased operational efficiency, performance, visibility and has added capacity and control. 

THE CHALLENGE 

Saramax Apparel had started to outgrow the capacity of its Pick-to-Light (PTL) tower and old conveyor system, which had earned Saramax the 2012 Walmart (DSDC) Supplier Award of Excellence. Its SKU quantity and volumes were increasing, which made the current system unsuitable for higher volume due to its poor conveyor path to shipping and lack of pick locations.  

The rest of the warehouse was filled with high bay VNA racking and the shipping staging space was at a premium. Walmart told Saramax that the only way in which they were to have any confidence in the numbers being met was if they used a more sophisticated system. 

 
Saramax needed a new multi-zoned picking system with minimal impact to the current warehouse layout while reusing most of the existing shipping conveyor system. Additionally, the new system had to be expandable at a mezzanine level and the conveyor layout pre-engineered for the future. It would require pick and pass capability between picking zones as well as a fast-track conveyor to the auditing area and shipping carousel loop, and it had to be installed without taking down the existing operation in a very aggressive schedule. 
 
“The single biggest challenge was keeping the footprint small,” Steve Lind, VP of Distribution, said. “We needed something like Disneyland to fit into the size of a playground.” 

 
As part of the consultancy approach, ELEMENT LOGIC analyzed the future SKUs and case data and created several system layouts that would fit within the available space, considering short distances for conveyor elevation changes, egress concerns and maintaining pallet storage location. 

THE SOLUTION 

 Element Logic provided Saramax with a new 36-bay, 28ft-tall, picking module, which was pre-engineered for a second level to allow for easy future expansion. Consisting of 648 locations, the first floor has central takeaway conveyors and overhead empty-carton-removal integrated with the existing trash compactor system. 

Due to short distances for elevation changes and complex paths between pick modules, the latest energy-efficient MDR spiral incline conveyors were utilized. These conveyors provide carton accumulation every 24’- 60’’, including inclines—maximizing peak rates and minimizing carton flow backup. 

 
Element Logic consulting services analyzed the SKU and order details and provided new SKU to location mapping for the existing and new pick modules to balance workload evenly between pick zones. Keeping the highest movers on the first floor provided the easiest replenishment option. 

” We increased productivity by about 500%, Lind added. 
We could not have predicted that it would go as well as it did! “ 

THE SYSTEM 

• The new system provides Saramax with all the pick locations required and order carton routing between pick modules. Pick rates are 800 – 1100 UPH and order accuracy almost 100% 

• Pre-engineering design features for the future will make expansion easy and cost-effective, while lost pallet locations have been minimized by adding overhead storage in the 28ft pick module racking. 

• The PTL system provides additional fine-tuning for zones and load analysis complete with reporting pick rates by employee, zone or other criteria. Saramax utilizes the Smart Auditing functionality that keeps track of all picking transactions for each order. 

ABOUT SARAMAX 
Saramax Apparel is a leader in design, production, and manufacturing of intimate apparel for over 40 years. 

The post Saramax: A Pick-to-Light System Case Study appeared first on Element Logic US.

Key Highlights 

The Element Logic Solution for LACOSTE 

CONSULTANCY APPROACH: Element Logic partnered with LACOSTE, and analyzed the data to help them decide which was the best-fitting solution to make their flow transition from B2B to B2C. 

AUTOMATED SOLUTION: Upgraded and integrated four software systems, the WCS, the unit distribution sorter, print and apply system, and shipping system. 

ENHANCED OPERATION: The solution has increased operational performance and efficiency, while reducing labor force by 30%-40% as well as costs. 

THE CHALLENGE 

As E-Commerce sales continue to rise across retail every year, LACOSTE has not been exempt from this phenomenon. There are many challenges that occur when adapting to run omnichannel as smoothly as possible. Often, finding the right solution includes a healthy dose of trial and error. 

LACOSTE originally went with a B2B solution, where they would send their product to a Distribution Center that also has an online platform, and they had their orders fulfilled and managed directly from there. Dealing B2B was not a match for LACOSTE because keeping the integrity of the brand became a challenge. LACOSTE was unsatisfied with the service they were receiving, the quality of packaging, fulfillment, and management of the product. 

Corporate was not satisfied, so LACOSTE started looking for a more efficient solution that could be achieved immediately and would satisfy both, corporate and the end customer. 

THE SOLUTION 

LACOSTE had to change the flow from B2B to B2C. Element Logic thoroughly evaluated LACOSTE’s needs, and decided to upgrade and integrate four software systems, including the WCS. Others included the unit distribution sorter, print and apply system, and shipping system. 

The solution had to maintain an 89.5% Service Level Agreement pick ticket within 24 hours. 

The project brought to life the vision of our business-to-consumer distribution, which is being realized today,” Beardsley added. 

The solution allowed LACOSTE to reduce their labor by 30-40% 

“It is essential for LACOSTE to fulfill our goal of becoming an Omni channel company,” 

Seth Beardsley, LACOSTE director of supply chain 

THE SYSTEM 

The system provided LACOSTE with an easy-to-use interface that has allowed employees to adapt and adopt it very quickly. ELEMENT LOGIC made sure to build flexibility into the system to allow it to effortlessly evolve with any future expansions. 

While SLA was supposed to be kept at 89.5%, LACOSTE never went below 90% on startup and currently sit at 98.49% due to human errors, not systemic ones. 

ABOUT LACOSTE 

Lacoste is a French clothing company, founded in 1933 by tennis player René Lacoste and André Gillier. It sells high-end clothing, footwear, perfume, leather goods, watches, eyewear, and most famously polo shirts 

The post Lacoste Case Study appeared first on Element Logic US.

Key Highlights 

The ELEMENT LOGIC Solution for Carter’s 

CONSULTANCY APPROACH: As part of ELEMENT LOGIC’s consultancy approach, we analyzed the issues and limitations that needed to be addressed to meet forecasted volumes and service requirements. 

AUTOMATED SOLUTION: Implemented a 600-drop dual tray SORTRAK machine. 

ENHANCED OPERATION: The solution increased accuracy, space efficiency, and the throughput capacity of the DC’s Omni-Channel fulfillment. 

THE CHALLENGE 

Carter’s has an existing distribution center in Braselton, Georgia, that uses a combination of a cross-belt sorter, shuttle system, put to store, and other automated systems to support their Omni- Channel facility. Retail store growth and increased replenishment was starting to out-grow the existing put to store automation. eCommerce also continued to grow with faster service requirements, making peak season demands more challenging. They needed a flexible sorter that could not only handle apparel, miscellaneous toys and baby products, but could also support Retail daily and adjust to eCommerce orders during peak times. 

This solution needed to be delivered in seven months (before peak), with minimal room for delays and working with their specific conveyor vendor. 

THE SOLUTION 

After evaluating Carter’s business needs and budget, the best solution at the right price point was to install a 600-drop dual tray SORTRAK to handle both, retail store distribution and eCommerce order fulfilment. The SORTAK was installed within a 25,000 square foot area and integrated with Carter’s existing conveyor vendor. The system consisted of 16 induction points capable of handling various induction modes, customized sorter height, and ELEMENT LOGIC’s DCMS software that interfaced with the existing WCS and WMS. 

ELEMENT LOGIC met material and manufacturing lead times and go-live by Labor Day 2017, in time for peak 2017. ELEMENT LOGIC’s project management, installation, controls and software group-maintained milestones during implementation and in partnership with the Carters PM team, ensured that there was the sorter was ready for Peak 2017. 

“Simplicity of design that makes understanding process, mechanics, and systems very clear to the team,” Kelly Bryson from Carters PM team said. “We have made some software enhancements to increase chute turnover and reduce impact of miss-picks.” 
 

THE SYSTEM 

ELEMENT LOGIC provided a SORTRAK machine to increase Carter’s order fulfilment capacity and utilize 14,400 trays per hour past a single point. The flexibility in this solution provided Carter’s with multiple induction options (i.e. Scan on the Fly induction, Presentation scanning, and Batch induction), while standing out from the others and having a good ROI. 

ABOUT CARTER’S 

Carter’s, Inc., also known as the William Carter Company, is a major American designer and marketer of children’s apparel. It was founded in 1865 by William Carter. Carter’s acquired competitor OshKosh B’Gosh. 

The post Carters Case Study appeared first on Element Logic US.

The UK’s leading football teamwear supplier saves over € 235,000 on floorspace, manpower and labor in its first year of using an AutoStore solution from Element Logic.

A series of firsts

Based in Dundee, Scotland, Direct Soccer is a family-run business and one of the UK’s leading football teamwear suppliers that offers in-house personalized printing and embroidery. By switching to online trading as early as 2002, it became the first company in Britain to take fully personalized orders on mobile devices.

Direct Soccer achieved another first nearly 20 years later – it became the first AutoStore user in Scotland and the second in the UK, placing it at the forefront of advanced warehousing. In its first year of using AutoStore, the company has saved approximately € 235,000 in floor space, manpower and energy savings.

The sportswear business’ growing customer base prompted its owners, husband-and-wife team Bryce and Joyce Gibson, to triple the floor size of the company’s warehouse in 2019.

While our manual racking system worked well up to that time, we knew we had to find a warehouse solution to optimize the floor space fully and improve the overall efficiency of our operations,

Bryce Gibson, Owner of Direct Soccer

Joyce continued: “Our online business caters for both clubs and individuals, so when the taps got turned off on the club side during the initial Covid-19 lockdown, we shifted our marketing focus to the individual. Using the mantra ‘stay safe, stay home, keep training’, we started supplying more leisurewear to this market through Express Football Kits, the sister site of Direct Soccer. The site offers next-day delivery with limited personalization and grew quickly.”

Bryce added that they initially considered a mezzanine system for the additional warehouse space, “but the number of floors made it impractical for our needs at the time.”

The road to automation via YouTube

Bryce and Joyce discovered Element Logic after searching for warehouse automation solutions on YouTube.

“We contacted the UK sales team, who came through the very next day,” says Bryce. “They assessed our needs and setup, and a week or two later, we went to Norway to see the AutoStore solution they specialize in, in action. We were thoroughly impressed with how straightforward the system was and how it could integrate with our current warehouse management system.”

We were thoroughly impressed with how straightforward the system was and how it could integrate with our current warehouse management system.

Bryce Gibson, Owner of Direct Soccer

Element Logic’s proposed solution appealed to Direct Soccer in several ways. The AutoStore system could utilize both height and floor space, and it would meet the company’s objectives of reducing lead times and increasing throughput. The system design also allowed for easy scaling in terms of performance and capacity.

Direct Soccer and Element Logic signed the contract in July 2020, and 16 weeks later, the system went live with seven robots and 8,000 bins, just in time for Christmas.

“The implementation process was well organized and took the concern out of what was a massive investment for us. The implications of it going wrong were immense, but we had complete trust in the Element Logic team from the outset,” Joyce emphasized.

“The team were knowledgeable, transparent, and quick to make and act upon their decisions. We couldn’t have asked for a better partner. The implementation took place in the extended section of the warehouse, so there was no interruption to existing operations,” Joyce added.

The team were knowledgeable, transparent, and quick to make and act upon their decisions. We couldn’t have asked for a better partner. The implementation took place in the extended section of the warehouse, so there was no interruption to existing operations.

Joyce Gibson, Owner of Direct Soccer.

With an entirely manual operation, Direct Soccer needed to use approximately 1,133 m² of floor space, but with an AutoStore solution just 210 m² – or less than a quarter of the existing space – is required. The company plans to expand the system to 16,000 bins in the future, which will be made easier due to the floor space savings.

High productivity and ease of use

“A major plus point of the system is its ease of use,” added Bryce. “We currently have 40 staff and regularly increase headcount – training can become a major problem when you’re scaling up. However, because of the systems seamless integration with our WMS, there’s a short training window. Everyone knows where to go and what to pick.”

Prior to the installation of AutoStore, the Direct Soccer warehouse averaged 10 orders despatched per hour. Now, they achieve 40 order despatches per hour.

Apart from building a multi-skilled work team for added flexibility during peak times, Direct Soccer also has five AutoStore superusers to do fault-finding if there are any issues with the system. However, regular services and strong remote support from Element Logic’s UK team ensure high reliability, so there had been little to no need to use the superuser backup.

“The peak period for Direct Soccer is July to September when the new football season gets underway,” said Joyce. “The automated solution allows us to manage these peaks, even with added stock volumes. It also enables us to introduce more stock-keeping units (SKUs) and reduce turnaround times.

“Currently, we have two conveyor ports and one carousel port, with most of the picking done from the latter. Sometimes we pick dispatch from the carousel port and production stock from a conveyor port. This flexibility means we can do jobs simultaneously, whereas before, we could only do it back-to-back.”

Enhanced customer experience

For the owners, the high throughput and ability to clear orders quickly are significant strategic benefits, since better customer service drives more sales. “We no longer have to put several people on orders. One operator can set up the entire process. And now we’re fulfilling 100% of fulfillment of in-stock orders for next day delivery,” explained Joyce.

In fact, because Direct Soccer are shipping orders direct from the AutoStore system, it has eliminated the need for these picks to move to a dispatch area. Plus, the putaway process is significantly faster and can match the pace of online orders, eliminating a build-up of stock waiting to be put away. This has saved the business the need to hire two additional staff members.

The speed and ease of use have encouraged Bryce and Joyce to look forward to the next stage of their automation journey. Currently, they’re considering automating the bagging machines in the dispatch area.

“We can now focus on other parts of the business that need improving. Every evening around five or six, I get excited when I hear the robots getting jobs ready to go out the next morning. It’s tremendously reassuring to know the operation keeps running while everyone else goes home,” Bryce concluded.

The post Football kit supplier scores big with warehouse automation appeared first on Element Logic US.

With a compact AutoStore system and implementation of a warehouse management system, Styleboom now has throughput and maximum flexibility in their new warehouse.

Styleboom is located in Geldern, Germany, and sells fashion clothing online under the brand Seventy-seven urban streetwear. As part of a fundamental restructuring, Styleboom moved into new facilities in 2020, and implemented warehouse automation and picking processes that increased their effi-ciency, capacity and optimized their processes.

“Our previous location no longer offered any possibilities for adapting the logistics to our rapid growing company,” Tomasz Stefanowski, Operations Manager Styleboom explains. “The customer orders were picked manually based on the article number in a multi-level shelving system. This resulted in high stress levels for employees, inefficient processes, and a high picking error rate, which was un-sustainable for our quality standards,” Stefanowski sums up.

The contract for the new logistics centre was signed early 2020, with an investor. In parallel, Style-boom replanned the logistics processes for the three planned warehouse segments and looked for an optimal automation solution for efficient storage and picking processes. Based on Styleboom’s needs AutoStore was the only option and Element Logic, was given the contract to implement it.

“The advantages of the system quickly convinced us. With an AutoStore solution from Element Logic, we were able to reduce the required warehouse area from 4,500 sqm of shelving to 1,300 sqm of floor space. The system was also designed exactly to the conditions of the 7.50 m high hall and can be scaled in terms of performance and capacity. The AutoStore system is the optimal solution for our requirements”, says Stafanowski.

60 to 70 percent improved space utilization

Three months after signing the contract, assembly could begin at Styleboom. The material was brought in just 5 weeks later, followed by a final testing and training phase. After a total of 25 weeks, the system was installed, linked to the newly implemented warehouse management system (WMS) and connected to their ERP system via an interface. The new site offers 8,160 m² of warehouse space, which is divided into three warehouse segments, in addition to 950 m² of office space, photo studio and social rooms.

Compared to other automated warehouse systems, this system enables a 60 to 70 percent improvement in space utilization. The loading stations are part of the storage cube and are accessed by the robots during off-peak periods.

6,000 orders shipped daily

Once picking is triggered by the WMS, employees can pick continuously. “Within three seconds, a new bin is presented in the port,” Stefanowski emphasizes with satisfaction. “The AutoStore system knows which bin is in which place, calculates the travel paths and then distributes the orders to the robots via a radio link. The robots work in a coordinated manner, quickly rearranging the bins, providing the required bin for direct access, and supplying the bins for the integrated ports for order picking.

The system is acting according to current ABC criteria: Less frequently requested bins are successively lowered to the lower storage levels, while fast-moving items remain on the upper levels for quick access.

The workstation modules consist of carousel ports for fast bin exchange, relay ports for ultra-fast bin exchange, e.g. order picking, and conveyor ports for slower bin changes, e.g. goods storage.

Expansion of the warehouse in mid-2021

In September 2020, Styleboom commissioned a basic system with 52,000 bins on 16 levels and 52 robots as well as seven carousel ports that can be used for goods both inbound and outbound. Due to the rapid increase in order volume and the disproportionate growth of the company of around 35 percent, the system was initially expanded by one port and four robots in the following months. Growing shipping volumes in the fashion sector generally also increased the volume of returns. In a second expansion, Styleboom increased the capacity of the warehouse in mid-2021 by integrating two extra ports and 20 robots. A total of 74 robots are now in operation in the online retailer’s logistics centre.

Picking and insertion take place at eight carousel and two conveyor ports – which enabled an increase in efficiency by a factor of 6. “With the system, 14 employees can pick the same volume of orders as 80 to 90 employees previously did with manual processes,” explains operations manager Stefanowski. “We efficiently pick 6,000 orders a day with zero errors and no back orders. This allows us to easily implement further growth without significantly increasing the number of employees.” In addition, there is software-supported end-to-end transparency over order processing. Finally, the picking processes at the ports are virtually self-explanatory thanks to display-based menu navigation. “Within 30 minutes, new employees can be trained and pick without errors,” Stefanowski adds.

“This means that the fully automated AutoStore system by Element Logic meets all the expectations we have associated with the automation of processes in terms of quality, increased capacity, efficiency and, managing the shortage of skilled workers. If necessary, we can also scale the system using various adjusting screws and adapt it to new requirements. We are highly satisfied with the results and the partnership with Element Logic.” Stefanowski concludes.

We are highly satisfied with the results and the partnership with Element Logic.

Tomasz Stefanowski, Operations Manager at Styleboom

The post Styleboom picks six times faster with AutoStore by Element Logic appeared first on Element Logic US.

Already a few months after NA-KD went live with its AutoStore solution empowered by Element Logic, they chose to expand to meet increased demand.

When NA-KD’s warehouse in Sweden, went live in July 2020, it had a storage capacity of 100,000 bins – where picking and storage was carried out with the help of 100 robots and 16 ports. In addition, Element Logic supplied NA-KD with conveyors and manual packing stations for consolidating goods from oversize. All packages are automatically sorted to different shipping suppliers with the help of a sorting system.

Ready for Black Friday

Already at the initial installation, they prepared a grid for another 25.000 bins, to be able to quickly scale up in case of increased need. After a very smooth start with the simple and flexible AutoStore solution, the design & analysis of an upcoming expansion began early. Ahead of Black Friday the same year, another 21 robots and 8 ports were installed to handle the increased growth. This is a good example of the flexibility of Element Logic’s AutoStore solutions where software, service and material flow handling solutions enable high availability, and scalability for any future expansions.

We had a chat with Fred Skantze, Head of Fulfillment at NA-KD.

In a very short time, we have managed to achieve good productivity even though the warehouse just started up

Fred Skantze, Head of Fulfillment at NA-KD.

Why did you choose to automate your warehouse?
– We wanted to optimize our warehouse space and productivity.

What is the result?
– The result has been good. In a very short time, we have managed to achieve good productivity even though the warehouse just started up approximately half a year ago. It has been relatively easy to get started and the operation has been successful.

How has Element Logic helped you before and during Black Friday?
– We got help with optimizing the system to achieve maximum productivity. Element Logic also had a technician on site during Black Week who helped us prevent problems.

How did Black Friday go compared to previous years?
– We had a very successful Black Week. Despite very large volumes, we managed to deliver all orders without any significant backlog.

How did your warehouse employees manage the new system?
– Since it is a completely new warehouse, we have had many workers who have never worked with AutoStore before. Nevertheless, it has been easy for our employees to quickly learn the system and achieve expected productivity.

Would you recommend AutoStore to other companies?
– Depending on the company’s conditions and targets, AutoStore is definitely a great warehouse solution.

Can you give a summary on your automation project?
– In a very short time, we built a completely new warehouse, implemented a completely new WMS system, IT infrastructure and installed an AutoStore system very successfully without any major disruptions. We would never have done everything we did in 7 months without very good partners.

The post NA-KD expands its automated warehouse a few months after launch appeared first on Element Logic US.

Despite having become one of the largest online outdoor specialists in Europe, Bergfreunde is still looking for new peaks to climb. And with a state of the art AutoStore system from Element Logic, the German company is setting its sights on new heights.

Clothes, shoes, outdoor equipment, in addition to climbing gear and other special equipment – Bergfreunde has it all. Having started their business in 2006, they currently offer more than 150.000 items from more than 750 different brands through their successful online store, and they continue to grow. With a sales increase of roughly 30 percent per year in 2017 and 2018 respectively, the ability to scale operations has been crucial – and will be for the years to come.

“With our tremendous growth we are dependent on a flexible and efficient storage system, which is why Bergfreunde.de has chosen AutoStore. Scalability, space efficiency and high performance were decisive factors for us. All our expectations on AutoStore and Element Logic have been more than fulfilled and we never regretted our decision”, says Ronny Höhn, Managing Director at Bergfreunde.

In August 2016, the company opened a new logistics center with a total space of 10.000 m2. The focus is on the self-sufficient AutoStore system, which was originally designed for a size of 1.800 m² and since then has been extended several times.

“The friendly market environment offers sustainable growth opportunities in upcoming years. We are planning further automation of logistics to increase efficiency gains”, Höhn continues.

Sorting in a high-density warehouse

At Bergfreunde’s logistics center in Rottenburg-Ergenzingen, south of Stuttgart, currently 80 robots are racing over the 3.000 m² system, moving 94.000 bins stacked in 16 levels. A total of 21 ports are available to move items in and out of storage. Divided by two shifts, more than 100 employees handle up to 200.000 items per workweek, taking care of incoming goods, returns and shipping. Bergfreunde.de store an average of three «Stock Keeping Units» (SKUs) per box.

“We are one of the very few AutoStore users in Europe that do not store our items in a sorted way. When people hear that, they look like they’re about to get a heart attack. But I can confirm that it works well. On the other hand, we have no choice: We can`t accommodate 200.000 bins and then only store two or three items per bin”, the company’s Logistics Manager Thomas Klein explains.

The new AutoStore CarouselPort 3.0 series

At Bergfreunde’s warehouse, the new AutoStore CarouselPort 3.0 series has already been installed, which is significantly more ergonomic than the previous version.

“This reduces signs of fatigue and makes the working environment more comfortable for the employees”, says Michael Kawalier, Managing Director Sales at Element Logic Germany.

Next level carton handling

In addition to all of the AutoStore components, Element Logic has also delivered and installed other equipment in the Bergfreunde warehouse to expedite handling. This includes automatic carton erectors, automatic carton infeed and outfeed, and final shipping sortation.

More specifically, this means that the order pickers automatically get ready-erected cartons delivered to their picking station. Upon completing the order-related task a delivery note with service information is automatically printed and attached to the carton. At the same time, the package receives an ID label. Afterwards on the conveyor belt, the parcel is automatically closed, weighed, optimized in volume, labeled, and handed over to the shipping department.

“With these additional elements, we significantly accelerated the process in the warehouse and noticeably increased the performance of the picking employees”, Kawalier says.

On average Bergfreunde’s employees are now completing 175 picks per hour. Before switching from shelf storage to Element Logic’s AutoStore-based intralogistics system, they could only do 45 picks per hour in comparison.

Bergfreunde has also opted to let Element Logic be responsible for the maintenance of their intralogistics system. The Service-Level-Agreement also includes hotline service, spare parts supply, and other services. This allows the company to focus singlehandedly on their day-to-day business operations.

Reaching a new peak in logistics in 2020

With the positive growth forecasts Bergfreunde is looking at now, their directors have already identified the need for another expansion of their logistics space in the near future.

“AutoStore requires about 10 percent of air in the system to be able to work properly, and we are already below 9 percent. That means that the air is slowly but surely starting to get tight again”, says Ronny Höhn.

The solution is to build a new logistics hall in the immediate vicinity of their existing warehouse. Here, an additional 10.000 m2 of space will be added by mid-2020. The new hall will contain the inbound area and the returns handling, as well as an extension of their existing AutoStore system.

“Adding an extension to an existing AutoStore system is extremely easy. In this specific case, we can connect the two storage units directly via a grid and rail for the robots”, Kawalier ends.

With the help of Element Logic, Bergfreunde has been able to increase the picking efficiency by more than 400%. In addition, the lead time from customer order to handover to the sender has been reduced to less than 3 hours. Today, the company processes more than 15.000 orders on peak days. The investment in the warehouse automation project paid off for Bergfreunde in less than two years.

The post Bergfreunde is increasing picking efficiency by more than 400% with the help of AutoStore by Element Logic appeared first on Element Logic US.

Eight years after the e-commerce and retail store for sports and fashion was founded, the increasing international growth and the consistent expansion of the product range in cross-channel sales required a new, more efficient logistics concept. With an AutoStore system empowered by Element Logic, eXXpozed was not only able to multiply its storage capacity, but also significantly optimize the processes within its warehouse in terms of reliability and efficiency.

eXXpozed sports & fashion offers high-quality equipment and clothing for outdoor and extreme sport. The company, founded in 2010, focuses on unique products of exclusive brands that aren`t available everywhere. They currently have a range of around 150.000 different items.

In December 2018, a new milestone has been added to the company’s history: eXXpozed opened a new building in the German Allgäu region, including a retail store of 750 m² and an adjoining bistro.

In addition, climbing and bouldering areas are offered on a total of 1.860 m² inside and outside, which are used for courses, events, and competitions. “We offer our customers a world of sports and outdoor, in which they can experience our products with all their senses”, states Andreas Oliver Bindhammer, who is not only founder and CEO of eXXpozed, but also a former world champion in difficulty climbing.

Looking for the optimal warehouse solution

From originally 4 permanent employees and 5 temporary workers in 2010, the number of employees at eXXpozed has now risen to more than 80. They are the ones who ensure that up to 1.400 orders a day find their way to almost 600.000 customers worldwide. In the first few years, eXXpozed operated in the traditional way of warehousing. The articles were manually removed piece by piece on request and picked according to the individual orders. The staff spent a lot of time putting the products together and as the range grew, the distances from the storage rooms to the shipping area became longer and longer. The rapid growth in the e-commerce business in addition to the retail store at the new location ultimately required more efficient processes and a higher storage capacity.

In the search for a future-proof logistics concept, various warehousing and logistics solutions were analyzed – but none of them seemed right for eXXpozed. „Until the day when the intra-logistics specialist Element Logic presented us with a solution based on the AutoStore concept: simple, space-efficient, smart and scalable – the perfect solution for our needs “, Bindhammer says.

Highest uptime on minimum space

After an implementation time of only 17 weeks, the space-efficient automatic storage and retrieval system, AutoStore was put into operation at eXXpozed in the late summer of 2018. Due to its compact design and high storage density, the AutoStore system was integrated one floor below the shop, on an area of only 450 m². “For comparison: a conventional warehouse would need around 3.500 m² to store the same quantity of goods”, explains Bindhammer. To make the special customer experience even more unique, eXXpozed has put the AutoStore robots into the spotlight: they can be observed from outside the building through a window.

After an implementation time of only 17 weeks, the space-efficient automatic storage and retrieval system, AutoStore was put into operation at eXXpozed in the late summer of 2018. Due to its compact design and high storage density, the AutoStore system was integrated one floor below the shop, on an area of only 450 m². “For comparison: a conventional warehouse would need around 3.500 m² to store the same quantity of goods”, explains Bindhammer. To make the special customer experience even more unique, eXXpozed has put the AutoStore robots into the spotlight: they can be observed from outside the building through a window.

Ergonomic workplaces and more efficient processes

Two carousel ports and one conveyor port are handling goods in- and outbound at eXXpozed. All workstations can be used for any process if necessary. This always provides eXXpozed maximum flexibility. The entire system is optimized by a software solution from Element Logic, which has been individually adapted to the needs of eXXpozed. Instead of using several storage rooms with long walkways, eXXpozed now has ergonomically equipped workplaces. The bins with the goods are delivered directly to the workstations, where pickers process both orders from the online shop as well as pick-up orders. Overall, for eXXpozed this means high efficiency with minimal effort.

If there is additional demand, for example before Christmas or on Black Friday, the performance of the AutoStore system can be increased at very short notice by adding more robots and storage bins. At peak times, the AutoStore system from eXXpozed was able to perform up to 370 picks / h.

A future-proof set-up

With the perfectly coordinated intralogistics and the resulting minimal order throughput time, eXXpozed is now able to meet the growing demand and customer requirements for fast and punctual delivery. Since the central warehouse is located directly under the retail store, eXXpozed can always also offer a very wide and deep product range in the store.

“In every respect, AutoStore and the collaboration with Element Logic have contributed to increasing customer satisfaction and further expanding our market position”, Bindhammer concludes. „For us, AutoStore by Element Logic was the best decision so far in terms of efficient and resource-optimized warehouse management. The fully automated warehouse fits perfectly into our existing infrastructure of our mail order software and thus guarantees us future security and sustainable growth opportunities.“

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