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.

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 Element Logic Solution for Abercrombie & Fitch 

CONSULTANCY APPROACH: Element Logic partnered with Abercrombie & Fitch to consolidate, optimize and reduce costs of their distribution operations within the confines of a specific footprint. 

AUTOMATED SOLUTION: The implementation of the automated Bombay sorter has improved the efficiency with which items were sorted and has reduced the labor force significantly. 

ENHANCED OPERATION: The solution enabled A&F to decrease their footprint, decrease costs and increase the accuracy of their operations. 

THE CHALLENGE 

In 2008, Abercrombie and Fitch had two separate Distribution Centers with Put-To-Light systems, which were no longer as efficient as they once were. A&F started to reevaluate its volume, efficiency and footprint, and decided to consolidate all the retail operations into one building. 

The UPH was in the low to mid 400s, while the packing function was in the mid-500s. 

The two DCs had to be consolidated into one 800,000 sq. ft. Distribution Center, the speed had to be improved, and it had to be able to handle peak volumes. 

THE SOLUTION 

After evaluating A&F’s needs and budget, it was decided that the best solution would be to install a SORTRAK Bombay sorter. While the option of bringing in two sorters was discussed, it was decided that one sorter that could sort to all store locations was the best solution for A&F. 

Overall department productivity almost doubled– going from low 400 UPH to mid-700 UPH, as well as the packing function productivity– going from mid 500s to low 1,000s. 

“When we built the sorter, we needed to be able to handle multiple units in a bag (prepack) in order to be able to handle peak volumes,” Todd Vallely, VP of Distribution said. “This really decreased the touches per item, one put is 4-6 units, so it allowed us to run even more volume on the sorter.” 
“We really like that it’s very easy to use, it’s not an overly complicated system,” Vallely added. “It’s fairly easy to train people and have them get up to speed with everything very quickly.” 
“We also came to Element Logic with different challenges,” Vallely said. “We wanted to use this sorter to sort direct-to-consumer orders, it was an out-of-the-box-thing and Element Logic’s been able to put together a plan that allowed us to do that successfully.” 

THE SYSTEM 

The new system was built inside a 900,000 sq. ft. DC and provided roughly an extra 200,000 sq. ft. of space through the building of a mezzanine. 

This allowed A&F to cut their retail packing footprint in half from the previous process (from 200,000 to 100,000), as well as helping them to dramatically improve UPH and use less than half the people they used in the past. 

ABOUT Abercrombie & Fitch 

David Abercrombie founded A&F in 1892 as an upscale sporting goods store. Forming a partnership with Ezra Fitch, the company continued to expand in the new 20th century. After Abercrombie left the company, Fitch became sole owner and ushered in the “Fitch Years” of continued success. 

After his retirement, the company continued under a succession of other leaders until 1977. Limited Brands purchased the ailing brand in 1988 and brought in Mike Jeffries, who revolutionized the image of Abercrombie & Fitch to become an upscale youthful fashion retailer. 

Today, the company is a multi-billion-dollar entity continuing to experience economic expansion through the business continuance of three offshoot growing concepts and cautious international expansion into key luxury markets. 

The post Abercrombie and Fitch Case Study appeared first on Element Logic US.

Finnish Design Shop, an online retailer of Finnish and Nordic design items, has been flourishing since its beginning in 2004. Now they offer over 300 brands and delivers to over 180 countries as a global leader in online Nordic design retail.

Its latest logistics center, situated in Turku on the southwestern coast of Finland, signifies its expansion. The need for a bigger storage facility led the company to embrace automation. Implementing the AutoStore system marked Element Logic’s first AutoStore project in Finland.

“Finnish Design Shop was the first online business in Finland to deploy AutoStore to develop and expand their business activities. A significant portion of global AutoStore users are e-commerce businesses, and in the Finnish market Finnish Design Shop is a pioneer”, says Antti Lumme, Managing Director in Element Logic Finland.

Kalle Karvanen, the Logistics Director at Finnish Design Shop, points out the automation trend, and specifically automation from AutoStore.

“AutoStore solutions have recently become more common globally as well as in Finland. Now, if you look at what kind of systems that are available in the market, you find all kinds of solutions, but it seems AutoStore is becoming more and more a standard, especially in the online retailing of small goods. I have seen all kinds of service providers and solutions during my career, and I can say without any reservations that AutoStore is one of the best”, Karvanen states.

I have seen all kinds of service providers and solutions during my career, and I can say without any reservations that AutoStore is one of the best.

Kalle Karvanen, Logistics Director at Finnish Design Shop.

Efficient use of storage space

Planning of the logistics center began in May 2020, with the Element Logic contract signed in February 2021. Renowned for its design, the facility was ready by fall 2021, featuring offices, a restaurant, a showroom, and the warehouse.

“When the Element Logic team arrived to assemble the grid, the building had not been finished yet. AutoStore was being installed at the same time as the building was finalized. It took three months overall to get the installation done”, Kalle Karvanen recalls.

Covering almost 10,000 square meters with a height of 11,7-meter, the warehouse’s design maximizes space thanks to the investment in AutoStore from Element Logic. Highlighting this, Karvanen states,

“The floor space of our warehouse is approximately 9 800 square meters. AutoStore is an efficient solution that allows for the maximum utilization of the floor space. Other solutions would not be able to even come close”, Karvanen says.

The order included the AutoStore system, 15 robots, 20,000 bins, 5 combined inbound/outbound ports, and a conveyor and sorting solution. The storage capacity has been expanded during the first two years of operation with 5,000 new bins. The delivery also included the software eManager developed by Element Logic. Optimized for the site, the solution can process approximately 350 lines every hour. The investment cost was just over 2 million euros.

Ergonomics and workplace safety

The AutoStore system has gathered substantial experience since the implementation Given the scale of the logistics center at Finnish Design Shop, Logistics Director Kalle Karvanen possesses valuable insights about the system.

“From the perspective of our users who deal with AutoStore every day, the operating system provided by Element Logic is easy to use and understand. It is very simple for the user to understand without undergoing days of training. We can get started with productive work quickly, which is important. As we operate in an industry with seasonal and volume fluctuations, we experience personnel turnover as well. And, as we sometimes use temporary workers, the short time needed for training of personnel is especially important”, says Karvanen.

Investing in automation can help employees in many ways by improving working conditions. Employees can handle products and orders quickly, safely, and ergonomically.

“One notable issue is safety. AutoStore is a CE-certified solution. Our workstations are at a suitable height. If we had gone for another solution than AutoStore, we would need to pick items more manually among forklifts, which would result in a greater risk of work accidents”, Karvanen summarises.

“Honestly, our experiences are very positive”

Element Logic seeks to make the installation, onboarding, and operation of AutoStore as easy as possible. After two years of use, Finnish Design Shop’s experiences with the partnership have been exclusively positive.

“Honestly, our experiences are very positive. Downtimes are short, less than what is specified in our contract, and the system has worked extremely well. I am not a person who would say this if it was not true. We have all been very happy and surprised with how well AutoStore works, how the robots can repair minor defects on their own, and how our employees have been trained by Element Logic.”

“Our users can resolve minor issues independently, and even in cases where more major problems have been encountered that we have not been able to solve ourselves, Element has provided valuable and timely support. They have taken initiative in dealing with problems, because they understand that in our line of business there is no time to wait for half a day for someone to solve the issue”, says Karvanen.

“We are in a partnership that works well both ways. We know how to propose new solutions or changes to existing operations, and these are always discussed with the customer’s business operations in the forefront”, Antti Lumme explains.

We are in a partnership that works well both ways. We know how to propose new solutions or changes to existing operations, and these are always discussed with the customer’s business operations in the forefront

Antti Lumme, Managing Director in Element Logic Finland

The importance of sustainable operations

Sustainability has played an important part in the design of the solutions. The footprint of the entire operation is exceptionally green, especially since the logistics center uses solar panels and geothermal heat to generate energy and heat. The low energy consumption of AutoStore and its long life cycle are an excellent fit with the Finnish Design Shop’s sustainability plan.

“Being sustainable in everything we do is important to us. Only the robots consume energy in an AutoStore solution, making it a very efficient system in terms of energy. Looking at the total carbon footprint, construction, bins, and robots all have their own impact. But, comparing this with the alternative solutions where all our goods would be placed on tall shelves with forklift trucks driving around, we can achieve a lower overall impact with AutoStore”, Karvanen estimates.

E-commerce is picking up speed

The objective for Finnish Design Shop is to enhance customer experience by ensuring fast delivery times, even as demand continues to grow.

“With AutoStore we can deliver faster than we used to, improving our customer experience. This is what will set us apart from our competitors”, says Karvanen.

Customers frequently highlight the swift delivery times of Finnish Design Shop in their feedback, greatly valuing this aspect. Additionally, the availability of products is a significant advantage. With an extensive range of immediately accessible items housed in their inventory, Finnish Design Shop ensures that customers do not face long waits to receive their products.

A solution-oriented approach

Kalle Karvanen is highly satisfied with the collaboration with Element Logic, particularly impressed by the agility and efficiency of their automation services.

“Whenever we have needed to make changes or implement certain additional features, we have received responses and cost estimates very quickly. This enables us to move our business forward as we get the responses we need for our calculations without having to wait. The Finnish organization of Element Logic works really well. With some other providers, you could throw the ball at them and then wait for three weeks to see if anything is going to happen. Not so with our current partner.”

Karvanen also has good things to say about the skills and solution-oriented approach of the Element Logic maintenance crew. He appreciates their efficiency, noting that they avoid unnecessary delays and swiftly provide the necessary solutions. Additionally, he highlights the reliability of the broader organization, emphasizing that when the Finnish branch’s resources are limited, support is readily available from corporate level.

“The system can be maintained one robot at a time and normal operations can be carried out during maintenance. This is an enormous benefit for us, compared to having to wind down the operations during maintenance”, Kalle Karvanen concludes.

The post Finnish Design Shop grows with AutoStore from Element Logic appeared first on Element Logic US.

AutoStore successfully met THG’s primary requirements, delivering a fast ROI. The impressive ROI time for the site exceeded expectations, with the initial investment cost recovered in two years.

The Hut Group (THG) is a world-renowned, vertically integrated e-commerce technology group based in the UK. Its flagship eCommerce software, Ingenuity, provides brands with comprehensive end-to-end solutions, empowering them to effectively tap into a vast global consumer base and thrive in the world of e-commerce.

The expansion journey

With a vast global fulfilment network consisting of 16 strategically located warehouses, THG enables shipping to over 190 destinations worldwide. In addition to its expansive shipping capabilities, the company goes above and beyond by offering support for over 300 localized websites, ensuring effective reach and exceptional service to diverse markets.

The Hut Group, having recently established a fulfilment center in Manchester, recognized the importance of implementing a warehouse automation solution that is both flexible and user-friendly, ensuring a rapid return on investment (ROI). With operations of such magnitude, requiring the handling of one million units daily, automation was the only viable solution. By prioritizing efficiency and adaptability, THG aimed to optimize operations and maximize the benefits of its new facility.

Learn about the key factors which drive warehouse automation ROI

The automation investment

The Hut Group made the strategic decision to invest in an  AutoStore system and enlisted the expertise of Element Logic for its installation. Element Logic completed the full installation of the AutoStore warehouse system within just three months – seamlessly integrating 256 robots, 13 conveyer ports and 56 carousel ports, as well as over 300,000 inventory bins. As a result, six weeks after installation, the grid system contained 10 million units.

In response to the increasing demands of its growing business, THG decided to incorporate an additional 124 robots into its AutoStore warehouse system, bringing the total number of robots to an impressive 380.  With an expanded robotic workforce and optimized warehouse system, THG is positioned to meet the challenges of its growing business with unmatched efficiency and productivity.

Learn more about how AutoStore can benefit your warehouse

Reaping the rewards

The implementation of an AutoStore system yielded immediate and significant results, greatly improving warehouse operations for THG.

Here are some of the results:

• Increased productivity: The adoption of AutoStore immediately boosted productivity, with a remarkable increase in order picking rates and significant improvement in picking accuracy. The system’s exceptional performance has virtually eliminated picking errors, resulting in a substantial reduction in labor requirements.
• Enhanced customer experience: The enhanced picking accuracy resulted in reduced errors and faster processing times, leading to improved customer order fulfilment and better overall customer experience. Consequently, this has positively impacted on repeat orders and customer retention rates.
• Reduced labor costs: Not only have THG reduced labor costs, but the company has also enabled employees to transition to more stimulating, value-adding roles. Moreover, with fewer staff members on the warehouse floor, the overall safety of the operation has increased, contributing to improved staff wellbeing.
• Return on investment: AutoStore successfully met THG’s primary requirements, delivering a fast ROI. The impressive ROI time for the site exceeded expectations, with the initial investment cost recovered in two years.

“The implementation of AutoStore at our Manchester fulfilment center has had a significant effect on customer satisfaction,” says John Gallemore, Executive Director and Chief Operating Officer, The Hut Group.

“We take pride in our partnership with THG to implement the transformative AutoStore system. The remarkable boost in productivity, enhanced customer experience, reduced labor costs, and rapid return on investment highlight the immense power of automation in optimizing warehouse efficiency,” says Jeremy Clouston-Jones, Managing Director, Element Logic.

The post Achieving ROI in 24 Months: The Hut Group’s Success Story 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.

For Travel Retail Norway, decreasing the picking time and utilizing available space was essential when choosing its next storage solution. The answer was AutoStore provided by Element Logic.

“It is impressive how much capacity Element Logic managed to create in our warehouse space,” Øivind Andersen says. Øivind is the logistics coordinator for Travel Retail Norway, the company operating the duty-free shops at Avinor’s largest airports.

The tax-free shops at Oslo Airport are very popular, and with limited storage space, TRN is dependent on smart and efficient solutions.

“After automating, customers can collect duty-free goods one hour after ordering. Previously, travelers had to order at least six hours before landing”, says Øyvind Andersen, Logistics Coordinator at Travel Retail Norway.

After automating, customers can collect duty-free goods one hour after ordering. Previously, travelers had to order at least six hours before landing

Øyvind Andersen, Logistics Coordinator, Travel Retail Norway.

Click & Collect tax-free products with AutoStore

Element Logic upgraded the Click & Collect service from TRN with a flexible AutoStore system.

“Several customers intended to shop with Click & Collect, but they did not have time to pick up the order due to the long waiting time. That is why automation was necessary for us”, Andersen explains.

TRN stores all the duty-free bestsellers in the AutoStore bins at Oslo Airport. In addition, they offer exclusive wines only available via Click & Collect, and the plan is to expand the range of exclusive products over time.

“AutoStore has increased our capacity, and we must use it. More Click & Collect orders equals less stress for customers and increased sales for us,” Andersen says.

“We see great opportunities”

Despite limited air traffic during the pandemic, TRN saw opportunities. When most shops and services surrounding Oslo Airport had to close, Click & Collect made AutoStore shine, and travelers could order duty-free products and collect them outside the store.

“We were able to offer a 15-minute delivery for duty-free products because of automated Click & Collect during this period. Our customers appreciated that,” Andersen says.

“Tax-free products and AutoStore are, without a doubt, a good match. We have several small items, and the opportunity for smart storage is worth its weight in gold”, says Andersen from TRN.

TRN is also considering using AutoStore to store products used daily for operations and maintenance for increased efficiency.

“Limited storage space is a well-known problem for airports around the world. AutoStore, with its modular and flexible solutions, is the answer to many challenges”, says Øyvind Kollerud, Sales Manager, Element Logic Norway.

Limited storage space is a well-known problem for airports around the world. AutoStore, with its modular and flexible solutions, is the answer to many challenges

Øyvind Kollerud, Sales Manager, Element Logic Norway.

Utilized each millimeter of storage space with AutoStore

The automation of TRN’s warehouse was challenging compared to other projects. Two important reasons were strict security requirements at the airport and a storage room with an unconventional floor plan.

In the design phase, the team made ten different proposals on how to build the AutoStore grid. The final solution ended up having the operator ports located in a tunnel inside the AutoStore, opposed to the more common location outside. This placement was one of the strategies to save as much space as possible for TRN.

There is room for 163 m3 with stationary shelves in the storage area, which is equivalent to 2,178 AutoStore bins. With AutoStore, the capacity has increased by 64 percent.

“To handle the same storage volume that TRN has with AutoStore, a 66 percent larger storage area would be necessary. That is 949 m2”, Kollerud from Element Logic explains.

“We have utilized each available millimeter in the storage area. The result is impressive space utilization and a solution that allows TRN to streamline its product flow from warehouse to the customer,” Kollerud says.

In an advanced project like this, preparation is crucial. As a big part of the system differs from standard measurements, the Element Logic team had to measure all dimensions precisely. The team measured several times to be one hundred percent sure that they set up the solution correctly.

“The team from Element Logic was able to adapt to challenges that occurred. It was a good collaboration, and the team always listened to our feedback”, says Andersen from TRN.

Element Logic:  The warehouse automation partner

In addition to challenging floor plans and small margins, fire safety is also different in TRN’s AutoStore system.

Customers often use sprinklers as fire protection in their facilities. TRN, however, uses FireEater due to strict airport security requirements. FireEater is a technology that reduces oxygen in case of fire. 

“It is exciting to be challenged by a customer on both solution and design. It makes it even greater when the customer says he is satisfied and impressed”, Kollerud says, and adds:

“As a customer of Element Logic, you do not just buy a service but also an automation partner that invests time to create the right solution. We appreciate it when a customer is involved and has requirements. That is when we get the best result”.

The post Oslo Airport streamlines its duty-free shopping with AutoStore 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.