One million square foot facility features an extensive suite of fulfillment technologies integrated by Element Logic, supporting one of North America’s largest and most advanced automated distribution operations.

VALENCIA, California — Element Logic and lululemon (NASDAQ: LULU) today celebrated the ribbon cutting of lululemon’s newest state-of-the-art distribution center (DC) in Brampton, Ontario, Canada. Spanning one million square feet, the facility represents the latest milestone in a 14-year automation partnership between the two companies and supports the fulfillment of lululemon’s growing e-commerce business across Eastern Canada and United States.

The Brampton DC features a major AutoStore system with 525 R5 pro robots and 292,000 storage bins, supported by approximately 24,000 linear feet of material handling equipment, an overhead monorail transport system, advanced omnichannel fulfillment technologies and a fully integrated software ecosystem. Together, these systems help support one of North America’s largest and most advanced automated distribution operations, strengthening lululemon’s ability to move product efficiently across stores and e-commerce. Developed and launched through a phased approach, the DC became fully operational in June 2026 following extensive planning, testing, training, and readiness activities. 

The Brampton facility—the largest AutoStore deployment in Canada and second largest in North America—reflects what is possible when long-term trust and technical execution come together at scale. We are proud to support lululemon with integrated automation that is designed around the needs of a complex, growing omnichannel network

said Krish Nathan, CEO of Element Logic Americas

The project reflects a comprehensive approach to automation, with AutoStore serving as the high-density storage and retrieval engine within a larger fulfillment environment. Element Logic’s role included helping bring together the robotics, conveyance, transport and software components needed to create a coordinated operation capable of supporting lululemon’s store and digital channels from a single large-scale site. 

“Since breaking ground in 2023, our new Brampton DC marks a significant milestone in the continued evolution of lululemon’s global supply chain. This facility expands our fulfillment capabilities in Canada and the U.S., enabling us to better serve our guests and operate with greater speed and agility.”

Ted Dagnese, Chief Supply Chain Officer of lululemon.

Element Logic first partnered with lululemon more than a decade ago on a modest automation project. That relationship has since grown into a global program spanning nine distribution centers across Canada, the United States and Australia, with Brampton serving as the partnership’s most ambitious project to date.

About Element Logic

Element Logic is a global technology company specializing in intelligent warehouse automation and software solutions. By integrating advanced robotics, data, and system orchestration, Element Logic helps customers unlock smarter, more efficient supply chain operations. For more information, please visit www.elementlogic.net/us

Media Contact

Gina Rotermund,

Head of Marketing

Element Logic Americas

Email: gina.rotermund@elementlogic.net

The post Element Logic and lululemon Mark Opening of One Million Square Foot Brampton Distribution Center, Showcasing 14-Year Automation Partnership appeared first on Element Logic US.

In the fast-paced world of e-commerce, efficiency and speed are critical to success. That’s why Kitch’n and Tilbords, Norway’s largest kitchenware retail chains, have built their operations around streamlined intralogistics. With 225 stores across the country and a strong direct-to-consumer e-commerce platform, their distribution center on Norway’s west coast plays a vital role in meeting customer demand.

We hold about 65% of the Norwegian kitchen and homewares segment” states Petter Grålumstuen, CTO and Logistics Manager for Kitch’n, Tilbords, & Cervera. He continues: “Our distribution center handled about 650,00 packages in 2024, and we have an assumed growth rate of 35% for 2025. With this growth we had no choice but to automate.” 

Our distribution center handled about 650,00 packages in 2024, and we have an assumed growth rate of 35% for 2025. With this growth we had no choice but to automate.

Petter Grålumstuen, CTO and Logistics Manager for Kitch’n, Tilbords, & Cervera

In 2021, Kitch’n and Tilbords implemented an AutoStore solution from Element Logic into their existing warehouse. This solution allowed them to automate the storage and picking process of the majority of their stock. With impressive growth since then, their manual outbound operations could no longer keep up, and Kitch’n and Tilbords once again turned to Element Logic to help them automate. 

“Kitch’n and Tilbords were looking for an automated solution which could transport articles away from the AutoStore ports during peaks. Our aim was to allow for an efficient downstream process that included packaging at pack stations before being sorted and distributed to the correct distributor.”  says Grålumstuen.

New Technology 

During the initial design and concept phase, various conveyor and sorter technologies were considered.  After analyzing Kitch’n’ and Tilbords’ data with expected growth, the new technology OmniMod empowered by Element Logic, was chosen as the ultimate solution for their needs. One of the key benefits of the OmniMod system is its capability to convey, sort, and buffer goods within a smaller footprint, compared to traditional conveyor technologies.  

“OmniMod is a newly developed modular system from a Norwegian startup empowered by Element Logic, that uses computer vision and AI to track and move items.” Brendon Wolk, Product Manager at Element Logic explained. “It differs from existing technology as items are free to move over the entire surface of the system. This enables it to not only conveyor and sort items, but additionally to buffer, group and sequence them.” 

This enables it to not only conveyor and sort items, but additionally to buffer, group and sequence them.

Brendon Wolk, Product Manager at Element Logic

“After an in-depth evaluation, we recognized that OmniMod was the perfect fit for our distribution center. In fact, the OmniMod design truly sets Element Logic apart. Their commitment to understanding the complexities of our operations—and their proactive, collaborative approach to finding the right solution—gave us great confidence. It was clear they were not just a vendor, but a true partner in this project” says Grålumstuen.

It was clear they were not just a vendor, but a true partner in this project

Petter Grålumstuen, CTO and Logistics Manager for Kitch’n, Tilbords, & Cervera

The automated outbound system designed includes conveyor, an OmniMod system, packing/value-add stations, and an outbound sorter. To keep the AutoStore as efficient as possible, items are picked first at the AutoStore ports and then packed downstream.

After an order is picked from the AutoStore, it is transferred via conveyor to the OmniMod system. Upon entry, each item is buffered into a pool of orders awaiting their next commands. Orders are then assigned to a packing station based on capacity and other customer-defined criteria. 

From there, the system diverts the orders to the appropriate packing stations, where fragile goods are carefully packed in bubble wrap and any value-added services are carried out. The operator then places the order back onto OmniMod, where it is automatically sorted toward the correct outbound shipping lanes. 

Throughout the entire process, every item is tracked in real time while on the OmniMod system. 

Robust Software

Today over 2000 orders per hour can be picked, packed, and sorted over the system. This success relies heavily on the robust software from Element Logic which manages and integrates the various components seamlessly. Element Logic’s software ensures that all parts of the process, from the starting order at the AutoStore, to the final palletizing of goods for dispatch, work together efficiently. 

The Results

The standout benefits of the automated outbound process from Element Logic are  

Reduced footprint by over 20%:

• OmniMod’s ability to convey, sort, and buffer goods, within one system, reduces the overall system footprint by over 20% compared to traditional technologies.  

Increased throughput capacity:

• The system significantly enhances throughput by processing over 2000 orders per hour, which is over twice the original capacity, enabling Kitch’n to grow their e-commerce business and handle higher volumes of orders. 

Speed:

• The complete automated outbound process is now 4-5 times faster than the original time required for picking, packing, and sorting, allowing Kitch’n and Tilbords to handle higher volumes of orders in a shorter time window

Scalability:

• The system is extremely flexible and can be easily extended to grow with the business’ needs. Any extensions can be up and running within 6 months of purchase order. 

Seamless integration:

• The Element Logic software is critical for coordination across all stages of the outbound process, from order receipt to final delivery. The result is a streamlined operation that minimizes errors, reduces manual intervention, and maximizes overall productivity. This reduced complexity resulted in a total installation time of under 1 month, which is significantly shorter compared to traditional technologies. 

Overcoming Space Constraints

Elements Logic’s automated outbound system and software have proven to be the ideal solution for Kitch’n and Tilbords. By overcoming space constraints, and automating the outbound process, the system is enabling growing business demands and ensuring they can continue to satisfy their customers’ needs well into the future. 

“Our future is looking very bright. Our new state-of-the-art facility from Element Logic, including the OmniMod system, has far exceeded our expectations. We are so impressed that we are already planning to expand the system by doubling the current capacity. This investment shows our commitment to technology that will improve our service level to our customers.”, says Grålumstuen.

Element Logic’s expertise in delivering systems like this demonstrates our technical capabilities and commitment to our customers.  Our ability to integrate and optimize state-of-the-art technologies like OmniMod not only showcases our relentless drive for innovation but also reinforces our position as a leader in the industry.

Brendon Wolk, Product Manager at Element Logic

Pilot Project with New Technology Exceeds Expectations

Read more about the related pilot project here

Read more …

The post An innovative solution from Element Logic helps automate Kitchn’s supply chain appeared first on Element Logic US.

Other

Unlocking the full potential of a warehouse lies in the seamless integration of technology and human expertise. Element Logic’s data-driven platform, eLogiq, enables businesses to transform warehouse operations through predictive analytics, real-time insights, and continuous optimization.

Companies like Aktieselskabet Carl Christensen (CAC) and EET Group have already seen significant value from implementing eLogiq, proving that the right data at the right time can revolutionize warehouse performance. “It is the combination of data insights and the proactive changes made by people that drives value creation with eLogiq”, says Stian Åsen, eLogiq Product Manager at Element Logic.

Driving continuous improvement with eLogiq at CAC

Aktieselskabet Carl Christensen (CAC), a leading distributor of car parts, operates two warehouses with AutoStore systems – one with 128,000 bins and another with 43,000 bins. For CAC, efficiency is key, and their Logistics Manager, Lars Riedel Jørgensen, emphasizes their commitment to ongoing improvement, “Data is the main focus we have right now. The key to doing things better than yesterday.”

Data is the main focus we have right now. The key to doing things better than yesterday.

Lars Riedel Jørgensen, Logistics Manager at CAC

With data at the core of their optimization strategy, CAC uses eLogiq to enhance storage utilization. By analyzing bin usage trends over time, they make informed decisions about increasing capacity or compressing goods. This not only impacts long-term storage planning but also daily operations. It ensures that replenishment happens at the optimal moment, reducing unnecessary handling, and maximizes efficiency.

Another key advantage is error prediction. With eLogiq, Lars does not have to monitor the AutoStore eventlog to predict potential robot failures – eLogiq does it for him! To further enhance this capability, eLogiq leverages machine learning to predict failures before they happen. In another pilot test, eLogiq reduced system stops by 45% in one month, saving 6.3 hours of downtime, a crucial improvement in operational uptime.

CAC is preparing to optimize staffing based on actual workload by considering factors like handling time, preparation rate, and port usage rather than estimates. eLogiq’s Staff Productivity Module offers this and will significantly enhance efficiency and resource allocation.

Identifying productivity bottlenecks at EET Group

For EET Group, one of Europe’s largest distributors of IT equipment, staff productivity was a critical area for improvement. Their logistics processes include necessary but time-consuming tasks such as serial number scanning, relabeling, and repacking. These are activities that impact pick times, and although they were aware of inefficiencies, pinpointing the root causes was a challenge.

That changed with eLogiq’s Staff Productivity Module, which immediately provided EET with surprising and actionable insights. “It was surprising when we saw that the temporary workers are the high performers”, says Niki Vesterlund Nielsen, Head of Logistics Development for EET Group.

This revelation allowed EET’s warehouse managers to refine their training processes, balance workloads more effectively, and focus improvement efforts where they would have the most impact. By addressing staff efficiency bottlenecks, EET can now reduce overall labor costs while maintaining high-quality standards, as well as expecting increased ROI.

Proactive Uptime Management: Preventing issues before they happen

Beyond addressing current inefficiencies, eLogiq also prevents problems before they arise. One of the most valuable features for customers like EET Group is Proactive Uptime Management.

Today, if a robot stops working, warehouse managers receive an email notification. But with predictive analytics, eLogiq can detect early signs of failures and alert the team before a breakdown occurs, allowing them to act in advance and prevent downtime.

System uptime is so important that Proactive Uptime Management is interesting even if we don’t have many errors.

Niki Vesterlund Nielsen, Head of Logistics Development for EET Group.

Additionally, Niki suggested an enhancement – a morning status email summarizing offline robots and their reasons. This insight is now being considered for future eLogiq development, illustrating how customer feedback directly shapes our product evolution and how the product team works closely with customers.

Future Innovations: Smarter port planning for greater efficiency

Element Logic continuously evolves eLogiq to offer even greater automation and data-driven decision making. One upcoming feature in development is Port Planning, which predicts required ports based on tasks and deadlines, filtering results by groups or queues for more precise workforce and workflow management. Transforming insights into tangible financial and operational gains is exactly the kind of ROI-driven innovation eLogiq is designed to deliver.

When presented with this concept, Niki’s response was immediate:
“If you can get that working, it’s worth a lot of money!”

Key results from eLogiq implementation

eLogiq is already proving its value in warehouses across industries, offering real business benefits.

• Storage optimization: CAC leverages eLogiq to analyze bin usage and improve capacity planning.
• 45% Reduction in downtime: Machine learning-powered failure prediction saved 6.3 hours of system stops in a pilot test.
• Staff productivity insights: EET Group identified inefficiencies and optimized workforce allocation.
• Proactive Uptime Management: Predicting failures before they happen ensures smooth operations.
• Future-proofing warehouses: Innovations like Port Planning promise even greater ROI.

Element Logic remains committed to maximizing warehouse success through progressive technology, predictive analytics, and customer-driven innovation. As we continue to refine and expand eLogiq, our goal remains clear: helping our customers achieve smarter, self-run, and data-driven warehouses.

The post The Value of eLogiq: Data-driven warehouse optimization in action appeared first on Element Logic US.

Continental, a global technology leader in automotive manufacturing and mobility solutions, took a significant step in advancing its warehouse operations by implementing AutoStore at its Periférico Plant in Guadalajara, Mexico.

(Read Press Release).

This state-of-the-art automated storage and retrieval system (ASRS) marks a new chapter in Continental’s pursuit of operational excellence and digital transformation.

Designed to optimize space utilization, enhance order accuracy, and improve productivity, the AutoStore system is a testament to Continental’s commitment to innovation and efficiency in its supply chain processes. With a focus on intelligent automation, the Guadalajara plant aims to set a new benchmark for streamlined operations in the automotive industry.

Challenge

Continental’s Periférico Plant faced a critical challenge: limited floor space that constrained its ability to efficiently manage inventory and meet increasing demand. As the company continued to grow and diversify its product offerings, it became evident that traditional warehousing methods were no longer sufficient.

“We started in 2001 in Guadalajara, Mexico. With 23 years of experience here at the plant, we are looking for an increase in quality of life for our employees.”

Sergio Márquez, Plant & Location Manager at Continental

The need for a scalable solution that could maximize storage capacity without requiring additional floor space became a top priority. Continental sought a system that could adapt to their evolving needs while ensuring seamless operations and high productivity.

Solution

To address these challenges, Continental turned to Element Logic. AutoStore, an ASRS known for its unique approach to warehouse efficiency and organization, has a modular design which allowed Continental to maximize storage capacity by utilizing vertical space. This effectively overcame the plant’s floor space limitations. The system’s high-speed robots efficiently retrieve items from a dense grid of bins, ensuring quick access to inventory while reducing strainful manual labor.

^{_{From left to right: Fernanda Morales Witrago, Communications Specialist at Continental; César Rodriguez Valadez, Advanced SCM Project Manager at Continental; Santiago Corona, Videographer; María Elena Ladrón de Guevara, Director of Marketing – Americas at Element Logic, María Luz del Alba Pérez, Head of Plant Communication & Executive Assistant at Continental, Sergio Márquez, Plant & Location Manager at Continental; José Luis Quezada, Head of Plant SCM at Continental; Salvador Nuñez, Material Flow Manager at Continental; and Santiago Corona, Videographer.}}

“The transfer times we had before AutoStore were much longer than they are today. We could not be happier with the performance. We have increased delivery of materials, both internal and external, by 67%”

Salvador Nuñez, Material Flow Manager at Continental

By implementing AutoStore, Continental was able to streamline its operations with an automated solution that enhanced inventory management, improved order accuracy, and increased overall productivity. The flexibility and scalability of AutoStore also meant that the system could be easily adapted to meet future growth, providing a long-term solution to Continental’s evolving warehousing needs.

Impact

The implementation of AutoStore has had a transformative impact on Continental’s Periférico Plant, driving both operational and employee-centric improvements. By optimizing storage capacity and automating repetitive tasks, the system has enabled Continental to handle larger volumes of inventory and meet customer demand more effectively. Order processing is now faster and more accurate, reducing errors and improving customer satisfaction.

“… we have greatly increased our security levels- which is a very important issue for Continental”

José Luis Quezada, Head of Plant SCM at Continental

“Continental has seen quite a few improvements.” José Luis Quezada, Head of Plant SCM at Continental said. “Once we implemented AutoStore, we began optimizing our resources as well as optimizing the workforce we have here. Additionally, we have greatly increased our security levels- which is a very important issue for Continental”

For employees, the shift to automated processes has significantly enhanced their quality of life. Tasks that were previously labor-intensive and physically demanding have been replaced by automated systems, reducing the risk of injuries and allowing staff to focus on more value-added activities. This has created a safer and more engaging work environment, fostering higher employee morale and job satisfaction.

Overall, AutoStore has equipped Continental with a future-proof solution that supports the company’s growth ambitions. The Guadalajara plant is now better positioned to scale operations, adapt to market changes, and continue delivering high-quality products efficiently and accurately. The successful integration of AutoStore underscores Continental’s commitment to innovation and operational excellence in a highly competitive industry.

Results

“Continental was looking for a highly efficient solution in a limited amount of space that would allow them to protect their products from debris.” Cristian Ahumada, Director of Operations – LatAM at Element Logic said. “Furthermore, they wanted a solution that had high processing rates. For all these reasons, AutoStore was the ideal solution for them.”

… AutoStore was the ideal solution for them.

Cristian Ahumada, Director of Operations – LatAM at Element Logic

Element Logic’s successful implementation of AutoStore at Continental’s Periférico Plant has delivered impressive results. The system has significantly increased space optimization, allowing Continental to make the most of its available warehouse area. Speed and efficiency have also improved, enabling faster order processing and reducing lead times. Additionally, the AutoStore system has proven to be highly reliable, ensuring consistent performance with minimal downtime. Its flexibility and scalability ensure that the system can adapt to future business needs, providing Continental with a robust and sustainable solution for long-term success.

The post Continental’s Story in Guadalajara, Mexico appeared first on Element Logic US.

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.

Freight Forwarding

Key Highlights 

The Element Logic Solution for Toll Group 
CONSULTANCY APPROACH: As part of Element Logic’s consultancy approach, we analyzed the issues and limitations that needed to be addressed. Toll Group found themselves in a situation where, after landing new accounts, they could not pick fast enough to meet expectations. 

AUTOMATED SOLUTION: Implemented a Put Wall system, transport conveyors, along with the software to interface with Toll Group’s WMS. 

ENHANCED OPERATION: The solution has increased speed, accuracy, space efficiency and increased the number of UPH. 

THE CHALLENGE 

Toll Group’s new account added 13,000 SKUs to their system, making it an arduous task to pick, at most, 20,000 units per day. In addition to this, Toll Group was on a short deadline and needed to meet a tight schedule, while constrained by a limited budget. 

THE SOLUTION 

After evaluating Toll Group’s business needs and budget, the best solution was to implement a Put Wall that would allow them to process 60,000 units per day. “We had another proposal by one of your competitors and they had a 26-week lead time,” David Hendrickson, Logistics Solutions Engineer, said. “But Element Logic knocked it out in about 13.” 

“The system is doing exactly what it’s supposed to,” Hendrickson said. “We can’t feed the beast fast enough.” 

THE SYSTEM 

Element Logic provided Toll Group with a Put Wall where each wall can handle a total of 40 orders fulfilling both retail and e-commerce.  

“On e-commerce we’ll run waves on orders of one, pick that in bulk and pack it,” Hendrickson added.  

A picker is assigned to an aisle and through it, picking everything the system tells them from the right and left. As the picker moves along, there’s another picker right behind them. If they pick at maximum, they pick six totes, and when the aisle ends, they drop their totes off by the wall.” 

They then go over the staging area to make sure all the orders are 100% complete, they put them on a conveyor and drops them off at the Put Wall area, where it’s automatically diverted to the right place. The operator scans the complete orders and they’re inducted into the wall where the lights lit up. Orders are packed, and when they’re done with the tote, they simply push it onto the belt. 
 

“The system is doing exactly what it’s supposed to,” Hendrickson said. “We can’t feed the beast fast enough.” 

ABOUT TOLL GROUP 

Toll Group, part of Japan Post, is a transportation and logistics company with operations in road, rail, sea, air and warehousing. Toll operates a network of 1,200 sites across 50 countries, with an Asia Pacific focus. 

The post Toll Group Case Study 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. 

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