Addverb 3PL Omnichannel Fulfillment Center
⭐Key Features
- •Integrated fixed and flexible automation solution for omnichannel (B2B & B2C)
- •AI-enabled WES for dynamic picking and routing strategies
- •Dual-layer sortation system (Zippy 25 robotic sorter) handling 3600 eaches/hour
- •Computer vision robotic systems for depalletizing and handling variable cartons
- •Ergonomic workstations and patented order consolidation system (Quasi solution)
- •Dedicated returns processing line with high flexibility
📊Results & Benefits
- ✓Increased capacity to 16,500 pallet positions and 86,400 tote positions
- ✓Achieves dispatch of 100,000 pieces per day to 2,500 unique destinations
- ✓Sortation rate of 3,600 eaches per hour
- ✓Streamlined returns processing and optimized order flow
📝Project Overview
Project Overview
Addverb partnered with a Third-Party Logistics (3PL) provider to revolutionize their omnichannel fulfillment operations. The primary objective was to create a seamless and efficient facility capable of handling the complex demands of both Business-to-Business (B2B) and Business-to-Consumer (B2C) order flows from a diverse SKU mix, including shoes (60%), apparel (30%), and accessories (10%).
The project focused on optimizing the use of the existing 330,000 square foot facility, prioritizing efficient order flow, and streamlining the returns process. The goal was to implement a future-proof automation solution that could scale with demand and handle high volumes with precision.
Technical Solution
Warehouse Execution System (WES) & AI Algorithms
The central nervous system of the facility is an AI-enabled Warehouse Execution System (WES). This software orchestrates the entire operation, utilizing intelligent algorithms for dynamic task allocation, picking strategy optimization, and real-time routing of Autonomous Mobile Robots (AMRs) and materials. It intelligently classifies incoming SKUs as B2B or B2C and routes them accordingly.
Momentum WES: Next-Generation Warehouse Execution and Control
Vendor: Honeywell Intelligrated
Key Features
The core innovation lies in the unique blend of fixed and flexible automation, allowing the system to adapt to fluctuating volumes and changing product priorities. The AI-powered WES enables real-time, data-driven decision-making for routing and task management, significantly boosting overall system intelligence and responsiveness.
The facility achieves remarkable density with 16,500 pallet positions and 86,400 tote positions. Its high-speed sortation and consolidation technologies are specifically engineered to manage the complexity of dispatching 100,000 pieces daily to a vast network of 2,500 unique distribution nodes.
Results & Benefits
The transformation led to a massive upgrade in storage and handling capacity. The facility now efficiently supports 16,500 pallet positions and 86,400 tote positions. Dispatch capability reached 100,000 pieces per day, seamlessly serving a sprawling network of 2,500 destinations.
Operational efficiency saw major gains with a sortation rate of 3,600 eaches per hour. The integration of automation, particularly AMRs, ergonomic workstations, and robotic systems, enhanced workplace safety, reduced physical strain on employees, and drove significant productivity improvements. Returns processing was also streamlined into a dedicated, efficient workflow.
System Integrator
Addverb was the complete system integrator for this project, responsible for the design, supply, integration, and implementation of the entire automation solution—from the Warehouse Execution System and AI algorithms to the Autonomous Mobile Robots, shuttle systems, robotic pickers, and sortation systems.
🔧Related Technologies (6)
Momentum WES: Next-Generation Warehouse Execution and Control
byHoneywell Intelligrated
TiltSort-Bot: Autonomous Mobile Robot (AMR) for Sortation
by Conveyco
Dark Warehouse: Fully Automated Warehouse Operations
byAddverb
Zippy Robotic Sorter: High-Speed AI-Powered Sortation
byAddverb
AMCAP: Automated Mixed Case Palletizing System
byDematic
Industrial Robot Arms in Logistics: Order Fulfillment Applications
byYaskawa
📚Related Knowledge Articles (6)
Robotic Piece Picking
Advanced robotic systems that use AI and computer vision to automatically select and pick individual items from diverse inventory, revolutionizing warehouse fulfillment operations with human-like dexterity and intelligence.
Pick-to-Light Systems
Pick-to-light systems use illuminated displays at storage locations to guide warehouse workers to the correct items and quantities, dramatically improving picking speed and accuracy.
Shuttle Systems
Shuttle systems use autonomous vehicles traveling on rails within racking structures to store and retrieve totes or cartons, providing flexible high-density automated storage with scalable throughput.
Pallet Flow Racking
Pallet flow racking uses gravity-fed roller or wheel tracks to automatically move pallets from the loading side to the picking face, ensuring perfect FIFO rotation for date-sensitive products.
Box Conveyor Systems
Box conveyor systems transport cartons and cases through distribution centers using belt, roller, or chain conveyors optimized for the consistent dimensions and weights of boxed products.
Pallet Conveyors
Pallet conveyors transport palletized loads through warehouses and manufacturing facilities using powered rollers, chains, or belts, enabling automated material flow between storage, production, and shipping areas.
