Automated Eyewear Manufacturing Facility

Objective

Their state-of-the-art Eyewear manufacturing facility handles a wide array of SKUs, consisting of 70% prescription glasses & eye frames, 20% contact lenses & solution, and the rest 10% divided between sunglasses and reading glasses.

Out of total more than 1,10,000 SKUs, 60% of the business volumes derives from Class A inventory, 30% and 10% of volume derives from class B and C, respectively.

In order to ensure customer delight, the order consolidation time had to be brought down to few hours, instead of the existing 2-3 days, while also focusing on reducing the cost and time of fulfilment.

Solutions

To fulfill the leading Eyewear Manufacturing Facility’s objectives and goals, Addverb helped in conceptualisation and designed a facility that would integrate manufacturing, warehousing and distribution.

To store the vast inventory and ensure fast picking, Quadron, Addverb’s carton-shuttle based ASRS was implemented, ergonomically designed Goods-to-Person (GTP) picking stations ensure efficiency and accuracy in order picking process.

Concinity orchestrates the automation systems to ensure on-time, in-full deliveries. SortIE, vertical sortation robot, was employed for physical store-based orders. For D2C orders, a fleet of robotic sorters was deployed to categorise orders into chutes as per logistics partners. Autonomous Mobile Robots are deployed to ensure the chutes are processed to the outbound area.

Key Performance Indicators

The extensive solution, incorporating a diverse range of robots to automate warehouse tasks, boasts unparalleled and impressive Key Performance Indicators (KPIs).

Order Consolidation time down to 2.5 hours/per order

Achieved order fulfilment accuracy of 99.99%

Efficiency of 2,00,000 orders dispatched/day

Optimised storage density with 32,000 storage positions

More than 40 GTP stations to ensure faster fulfilment.

Capability to scale to store up to 3,50,00,000 eaches in future.