50,000 Orders Daily: Lojas Renner’s Omnichannel Fulfillment
How do 220,000 SKUs, millions of items and thousands of orders for stores, online and click-and-collect customers get to the right place at the right time? For Lojas Renner, a leading fashion retailer in Brazil, the challenge was to handle changing collections, volumes and priorities while mastering the logistical complexity and combining all sales channels into a single process at their distribution center in Cabreúva.
Lojas Renner required a solution that would help them stay on top of stock, control orders across channels and combine the processes for flat-packed goods and hanging goods in one system. The answer was a highly automated omnichannel fulfillment solution featuring five pocket sorter modules that process store, e-commerce and click-and-collect orders in one seamless omnichannel fulfillment process. Combined with the Evo Shuttle 1D, matrix sortation and our intelligent KiSoft software, the automation solution achieves omnichannel order fulfillment in an end-to-end process. This allows Lojas Renner to handle up to 50,000 orders per day, deliver the goods to their destination reliably, achieve high goods availability and offer a fantastic shopping experience across channels.
163,000 m² (approx. 1,755,000 ft2) warehousing space
50,000 orders per day
220,000 SKUs
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More InformationWe were looking for a partner who would understand the complexity of our business. We found such a partner in KNAPP.
Ricardo Schilder Lima
Director Logistics, Lojas Renner
If customers don’t think in channels, why should your logistics?
Combine stock, orders and material flows into one seamless omnichannel fulfillment process with our solutions.
Benefits of omnichannel logistics: More availability, speed and flexibility
Personalized distribution
Flexible store fulfillment
Rapid, reliable delivery
Maximum flexibility and productivity
The Matrix Sorter is a great advantage. It accelerates throughput and significantly increases flexibility.
Ricardo Schilder Lima
Director Logistics, Lojas Renner
Ready for fashion fulfillment across channels?
Let’s make it a reality.
Central warehouse processes –
omnichannel fulfillment for hanging and flat-packed goods
1) Goods-in
Hanging and flat-packed goods are delivered to the DC separately and digitally recorded in the goods-in area. The two types of goods are then fed into the right material flow.
Flat-packed goods are unpacked and placed into storage containers and stored in the automated storage system, while the hanging goods are equipped with an RFID transponder, which allows them to be identified and seamlessly traced throughout the garments-on-hangers process.
2) Flat-packed goods
Flat-packed goods are buffered in the flat pick tower, a buffer tower dedicated to this type of good. The goods are recorded digitally at the decanting stations, repacked into containers and stored in the Evo Shuttle 1D. As soon as an order is started, the right containers are retrieved from the Evo Shuttle 1D, and separated at the pocket induction stations, where individual items are loaded into the EcoPockets. The full cases coming out of the flat pick tower can also be fed into the pocket sorter system.
Three EcoPocket pocket sorter modules are dedicated to store orders, while two pick e-commerce orders. Items are put into the right sequence using matrix sortation and conveyed to the pack station.
3) Hanging goods
Every garment is equipped with an RFID tag, allowing them to be identified and seamlessly tracked. In the GOH pick tower, the hanging goods are buffered and provided for sorting according to order .
The GOH sorter sequences store orders using matrix sortation. For e-commerce orders, the e-commerce sorter merges the hanging and flat-packed goods while putting them into the right sequence.
4) Goods-out
Once packing is completed, the shipping sorter sorts the e-commerce, click-and-collect and store orders according to destination and order type and prepares them for shipping. Never-out-of-stock items as well as full cases are picked from the flow rack and conveyed to the goods-out area by the shipping sorter.
Around 4,700 orders per hour leave the DC for delivery to Brazil, Argentina and Uruguay.
Returns management
Returns from end customers or stores are registered in goods-in and transported to the returns warehouse, a static storage area. There, they are digitally recorded and packed into storage containers for putaway. If a returned item is needed for a new order, it is taken from the storage container and transferred to a pocket induction station. From this station, the item is inducted into the pocket sorter for sorting and picking.
orders
orders
pocket sorter modules
storage locations
Pocket sorter system combines store and e-commerce orders into one goods flow
At the heart of the sorter are five pocket sorter modules: three for store fulfillment and two for e-commerce orders. Using matrix sortation, the pocket sorter puts randomly buffered items into the right sequence reliably. The Evo Shuttle 1D supplies flat-packed goods for further processing. Order consolidation buffers combine items from different warehouse areas with different picking speeds to ensure steady throughput and avoid slowing down the sorting and packing processes.
KiSoft controls the material flow in order to achieve a balanced workload, while KiSoft Analytics provides important system data and supports decision-making through real-time monitoring, trend analyses and prognoses, creating maximum transparency. Thanks to integrated fulfillment processes, the performance of Lojas Renner’s system stays high, even during seasonal peaks, when new collections arrive or order volumes increase.
- 5 pocket sorter modules for store and e-commerce fulfillment
- One material flow for store, e-commerce and click-and-collect orders
- Hanging and flat-packed goods handled in one system
- Order consolidation buffer for goods picked at different speeds
- End-to-end process control and transparency thanks to KiSoft
Partnerships make complexity simple
The distribution center in Cabreúva is Lojas Renner’s first highly automated logistics center. Instead of implementing an off-the-rack solution, Lojas Renner opted to partner with KNAPP to create a tailored all-in-one solution for their omnichannel fulfillment. The solution is scalable, paving the way for future growth and transformation.
