Fulfillment Rates boosted 150% for Outdoor Network

«We had some target rates that we wanted to hit at the Ports and per staff member. We were actually able to surpass all of those simulations and surpassed our own goals.»

Jon Nance
Director of Distribution, Outdoor Network

The Challenge: Overcome Bottlenecks to Meet Surging Demand

Outdoor Network's East Coast Distribution Center in Georgia was struggling to keep pace with increasing order volumes. As Jason Rindge, Chief Operating Officer at Outdoor Network, explains, "We couldn't grow anymore in our other environment. Our revenue was going to be stagnant... There was no pushing it anymore in the environment we were at."

Issues that threatened the company’s growth and operational efficiency included:

• Fragmented inventory storage: Outdoor Network's inventory was split between two facilities — one for small parts using goods-to-person (GtP) horizontal carousels, and another for large items. This made consolidating multi-line orders complex and time-consuming.  
• Outdated technology: Existing horizontal carousels were approaching end-of-life and could not meet the processing capacity required for peak demand periods. And the warehouse management system (WMS) was outdated, further complicating operations.
• Labor constraints: A significant surge in demand coincided with difficulty in staffing two shifts, further straining fulfillment operations.
• Supply chain disruptions: Outdoor Network was not immune to global supply chain challenges. Many parts were frequently unavailable for extended periods, adding another layer of complexity to inventory management.

The company needed a solution that could increase efficiency, reduce labor dependency, and streamline order processing.

Outdoor Network now has a highly efficient, scalable fulfillment operation capable of meeting surging demand and adapting to future growth. | Source: KPI Solutions

The Solution: AutoStore — A Comprehensive Automation Powerhouse

To address its challenges, Outdoor Network implemented an AutoStore system at the center of a fully integrated automation ecosystem. The system comprises:

• A dense storage Grid spanning 1,300 m² (14,000 ft2)
• 28,700 Bins stacked 11 high, efficiently managing over 80,000 Stock Keeping Units (SKUs)
• 75 Robots for continuous retrieval and restocking of inventory
• 14 Goods-to-Person (GtP) picking Ports for efficient order fulfillment
• 10 restocking Ports for seamless efficient management

The AutoStore solution integrates with other automated technologies to create a holistic fulfillment ecosystem:

• Autonomous Mobile Robots (AMRs) transport oversized items between static shelving and pallet racks
• Automated packaging systems create right-sized trays for multi-item orders
• Tabletop autobaggers efficiently package single-item orders
• Conveyor systems streamline both restocking and picking processes, moving SKUs, picking trays, and completed orders through the facility

This integrated system is faster and more efficient, significantly reducing manual labor and walking distances. Robots deliver items directly to workers at picking Ports, while restocking is handled through dedicated Ports, with Robots managing storage within the Grid.

The AutoStore solution integrates with other automated technologies to create a holistic fulfillment ecosystem. | Source: KPI Solutions

Key Benefits: Transforming Fulfillment Performance and Scalability

Outdoor Network now has a highly efficient, scalable fulfillment operation capable of meeting surging demand and adapting to future growth. Significant improvements include:

• 150% increase in throughput: Up to 22,500 daily picks, surpassing previous peak volumes
• High-density storage: AutoStore’s ultra-dense, cube-based storage system allows Outdoor Network to store over 80,000 SKUs in a compact space.
• Faster, streamlined operations: With 14 picking Ports and 10 restocking Ports, AutoStore reduces bottlenecks and speeds up processing times. Orders for in-stock inventory are processed, packed, and shipped within 15 minutes.
• 50% reduction in labor dependence: By consolidating operations into a single shift and automating key processes, Outdoor Network decreased labor dependence by 50% and allowed employees to focus on higher-value tasks
• Dramatic increase in safety stock: Ultra-dense storage provides buffer against supply chain disruptions
• Near-perfect accuracy: With AutoStore, Outdoor Network has significantly improved order accuracy and reliability, ensuring near-perfect accuracy in order processing.

A New Era of Efficiency for Outdoor Recreation Retail

By dramatically increasing throughput, optimizing storage, and reducing labor dependence, AutoStore solved immediate operational challenges and positioned the company for sustainable growth. It’s a transformation that showcases how cutting-edge automation can ensure faster delivery times, improve accuracy, and enhance customer satisfaction.

Project Specifications

• Implementation type: Brownfield (existing site)
• Robots: 75 Robots
• Workstations (Ports): 14 Ports for picking, 10 Ports for inventory replenishment
• Bins: 28,700 Bins
• Grid size: 1,300 m² (14,000 ft2)
• SKUs: 80,000 SKUs stored in AutoStore, 110,000 SKUs overall
• Partner: KPI Solutions
• Integrated technology: Conveyor technology, Geek+ AMRs, Sealed Air I-Pack systems