Automated Omnichannel Fulfillment for the DOUGLAS Group
As one of the leading 3PL companies, Arvato develops tailored solutions for their customers and relies on innovative technologies. Working with Arvato, we have already implemented quite a number of installations, always keeping the customer and their requirements in focus. The omnichannel automation solution for the DOUGLAS Group in Germany is a perfect example of this philosophy.
The DOUGLAS Group is Europe’s leading omnichannel premium beauty supplier offering a range of fragrances, makeup and skin and hair care products. To better support the group’s omnichannel strategy and facilitate growth, they implemented an automation solution in 2022 to process orders for Germany, Austria and Switzerland. “One warehouse – all channels.” The idea was to consolidate all six warehouses in one central one, which would process all sales channels and the various order structures.
I am very satisfied with the KNAPP system. This solution is everything we could wish for with respect to our existing requirements.
Pedro Duran Garcia
Director of Logistics Planning, Arvato
Are you looking for an efficient solution for omnichannel fulfillment?
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From challenges to successes
KNAPP is a reliable partner for Arvato and we develop together.
Sebastian Altrogge
Key Account Manager at Arvato
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Smart warehouse design for an optimal flow of goods
The omnichannel automation solution for the DOUGLAS Group focuses on maximal automation and handling premium beauty products gently while storing them securely, as they are considered dangerous goods. It is an exceptional, comprehensive automation solution thanks to the variety of different technologies featured, which are all physically integrated and intelligently networked together.
1) Goods-in
The incoming cartons are either stored in narrow aisle pallet racking or are conveyed directly to one of the 28 decanting stations. MultiScan automatically records important master data for unknown items and transmits it directly to the WMS. This makes the further processing of items in the warehouse highly efficient.
At the decanting stations, the system suggests one of the four container configurations for storing the items. Empty containers are supplied to these stations either from the empty container buffer or from the shuttle system. The filled new storage containers are pushed onto the take-away conveyor by an employee and transported towards the shuttle system.
2) Storage
In Arvato’s small parts warehouse, the 550 shuttles of the Evo Shuttle 2D system store and retrieve 12,500 containers per hour across 25 levels and 22 aisles. Almost all of the 70,000 SKUs are stored double-deep in this huge shuttle system. After retrieval, containers are transported to the corresponding lift system, which sends them onward for further picking at goods-to-person work stations. This system flattens peaks and makes stark differences in order structure easy to manage.
3) Picking
What’s more, nine different carton sizes are available for B2C orders. Depending on the order size, the right carton is automatically erected and fed via the order-start cross-belt sorter to one of the 32 work stations of the Pick-it-Easy Evo series. These goods-to-person work stations allow employees to access two source containers and four order cartons simultaneously.
After goods are retrieved from the shuttle and picked at the Pick-it-Easy work stations, cartons can be conveyed to the fast-mover area or the sample area. The manual picking stations in these areas utilize a Pick-to-Light system. Up to 15,000 samples can be picked in the sample area per day and other value-added services can be handled at the value-added service stations. Large items for B2B orders are added at the manual stations where oversize products are picked.
4) B2B shipping
After being manually secured for transport and automatically given a shipping or dangerous goods label, the B2B orders are shipped to the DOUGLAS Group stores in Germany, Austria, and Switzerland.
5) B2C shipping
Once picked, the B2C orders go directly to transport securing where filling material is added to the carton. This process is carried out at eight Pick-to-Light stations. At the goods-out sorter, the orders are diverted to the automatic carton closers and automatic labelling stations and finally on to the shipping ramps from which they are loaded.
order lines per day
SKUs
2D shuttles
storage locations in the automated storage system
Optimal storage density in the world’s largest 2D shuttle system in beauty
At the center of the automated omnichannel fulfillment solution for the DOUGLAS Group is our all-in shuttle. The Evo Shuttle 2D automated storage system is perfectly suited for streamlining the logistical processes in the warehouse and boosting warehouse performance.
We designed the system for the double-deep storage of 132,000 source containers. In the 2D system, each of the 550 shuttles remains on one of the 25 levels, but can move crosswise between the 22 aisles. Every source container can be transferred to the respective lift system to ultimately arrive at the selected goods-to-person work station. The pre-zone in the system is reduced to a minimum, which in turn makes optimal use of space to achieve a greater storage capacity.
Software excellence for smooth, efficient processes
Arvato relies on our KiSoft One logistics software for smart, error-free warehouse processes.
KiSoft Analytics, a special feature of the solution, allows Arvato to keep track of all the relevant system data, helping Arvato detect trends and create prognoses while providing important real-time data during the startup phase.
What’s more, our computerized maintenance management system KiSoft CMMS assists Arvato in decisions surrounding maintenance and spare parts management. Should a malfunction occur, our software solution KiSoft SCADA is there to assist.
