Their facility handled a wide array of SKUs and needed a solution that promised accuracy and efficiency. Their inventory consisted majorly of 60% footwear, 30% apparel, and 10% accessories making inventory control a complex affair. Their objective was to develop a robust solution that could efficiently manage the operations, reduce dependency on manpower, and simultaneously save costs.
Their requirements included a complete process from receiving material, put-away and retrieval, followed by each and case picking, order consolidation and sortation for quick dispatch according to the assigned destination. The solution had to be flexible to cater to B2B as well as B2C customers to facilitate omnichannel fulfilment. Also, they wanted to have a planned reverse logistics process to streamline all the returns from different channels and manage inventory accurately. To manage the complete end-to-end operations of the warehouse they needed a one-stop solution, for enhanced synchronisation and smooth information flow.
Due to the rapid scaling up of their brand and the rising demand, they urgently needed to incorporate a greenfield solution in a brownfield. To achieve all their objectives, Addverb designed an innovative solution that combines the power of both fixed and flexible automation.
The solution comprised of Autonomous Mobile Robots for material movement in the warehouse, Automated Storage and Retrieval Systems like Pallet Shuttles and Carton Shuttles to optimise space utilisation. For automated material transfer and returns handling, Multi- Carton Picking vehicle was added along with sorting robots for quick dispatch of orders and cater to B2C customers. Additional systems like mixed case palletisers, Pick-to-Lights, and strategically planned conveyor lines helped in the seamless integration of fixed and flexible automation.
For a solution this large and involving a wide array of robots to automate the operations of the complete warehouse, the KPIs are unmatched and enviable across all fashion brands.
100,000 pieces dispatched per day to 2500 unique distribution nodes
Pick-to-Light technology for efficient palletising operations with up to 60 available open pallet positions
16500 pallet positions for multi-deep storage and retrieval of pallet loads
86400 tote positions to maximise throughput in storage and retrieval of totes
Robotic depalletiser that can perform depalletisation of up to 420 cartons/hour/robot
AMRs and Multi-Carton Picking Mobile Robots for swift movement of material in the warehouse with minimal human intervention
Double-layer sortation system where 3600 eaches are sorted per hour and there are 300 bin locations with 150 on each level
Warehouse Control System to manage the end-to-end operations in a warehouse
Our extensive product portfolio helps us design customised solutions for varying industry requirements.