AutoStore Optimizes Omnichannel Operations for Rogers Sporting Goods

Rogers Sporting Goods, a family-owned omnichannel retailer specializing in hunting and outdoor gear, operates a retail store in Liberty, Missouri, and an 18,860 m² (203,000 ft²) distribution center in Kansas City. Faced with growing e-commerce demand and the need for faster, more efficient store replenishment, Rogers partnered with AutoStore, empowered by KPI Solutions, to enhance their order fulfillment capabilities across both channels.

AutoStore's cube-based system has allowed Rogers to expand capacity within their already limited floorspace, while simultaneously managing both retail store replenishment and e-commerce fulfillment. By automating key processes, Rogers Sporting Goods has significantly improved productivity, streamlined operations, and reduced order turnaround times for their brick-and-mortar and online channels.

The Challenge: Expanding Capacity and Efficiency within Limited Space

Rogers Sporting Goods was at a critical juncture following its relocation of their distribution center to a new 18,860 m² (203,000 ft²) center in Kansas City, Missouri. Despite the move to larger premises, the company faced significant challenges stemming from rapid growth and Stock Keeping Unit (SKU) proliferation. The new facility, while spacious, was quickly becoming constrained as the company's product range expanded to meet diverse customer needs.

The company needed to increase storage and processing capacity without further expanding their physical footprint. The spatial constraint was compounded by the pressing need to enhance operational efficiency, particularly in two critical areas: The company's twice-weekly store replenishment process for their Liberty, Missouri retail location was becoming increasingly time-consuming and labor-intensive. And Rogers was grappling with the demands of a burgeoning e-commerce business, which required faster order processing to meet customer expectations. These challenges were limiting their continued growth and competitiveness.

Rogers was under mounting pressure to reduce lead times, optimize their labor force, and ensure accurate, timely order fulfillment across both their retail and online channels, and recognized the need for a solution that could address this within the constraints of their existing facility.

The Solution: AutoStore's Cube-Based System for Omnichannel Fulfillment

After evaluating several Automated Storage and Retrieval technologies, Rogers Sporting Goods selected the AutoStore cube-based system to address their e-commerce order fulfillment and retail store replenishment challenges. AutoStore was chosen for its ability to maximize storage density and streamline picking processes within the existing facility. The system comprises 22 R5 AutoStore Robots, 51,000 storage Bins, 4 multipurpose Ports (Workstations) for both picking and replenishment, and KPI Solution’s Kommand AS software for system management.

This configuration allows Rogers to make optimal use of their available floor space by densely storing goods vertically, while robots ensure efficient goods-to-person retrieval. The system's flexibility enables it to handle both e-commerce orders and individual product picks for the Liberty retail store.

The AutoStore system is integrated with a put wall for order sorting and consolidation, and an autobagger to streamline the packing process. The entire operation is orchestrated by the Deposco Warehouse Management System (WMS), which manages order processing and inventory across both retail store replenishment and e-commerce fulfillment channels. This integrated solution provides Rogers with a unified platform that ensures coordination between the AutoStore system and Rogers' broader inventory and order management processes.

Rogers Sporting Goods’ distribution center is now a highly efficient, space-optimized fulfillment hub capable of meeting all the needs of its omnichannel retail operation.

Key Benefits: Fast Efficiency and Dense Storage

The implementation of AutoStore's automated storage and retrieval system has delivered significant improvements across Rogers Sporting Goods’ omnichannel fulfillment processes, including:

• Faster e-commerce order turnaround: Orders are now processed and shipped in 24 hours, a 50 – 66% improvement from the previous 2 – 3 day timeframe, even during peak seasons.
• Improved retail replenishment efficiency: Picking times for store replenishment have been cut by 50%, enabling more frequent restocking with less effort.
• Expanded capacity: AutoStore's cube-based design maximizes space use, allowing Rogers to increase storage capacity without expanding their physical footprint.
• Increased productivity: The system now operates with fewer full-time equivalent employees (FTEs), reducing the need for additional staff while improving the volume of orders processed.
• Increased inventory accuracy: Automated inventory management has significantly reduced errors, enhancing operational efficiency.
• Versatile omnichannel fulfillment: A single AutoStore system efficiently handles both retail store replenishment and e-commerce orders, streamlining operations across all channels.

From Warehouse to Powerhouse

Rogers Sporting Goods' ecosystem is now cohesive, flexible and scalable, ensuring the company can easily adapt to changing market demands. With omnichannel fulfillment capabilities that enhance customer satisfaction across sales channels, Rogers can continue to expand without the need for additional space. It’s a forward-thinking approach to warehouse automation that positions the company for continued success in the evolving retail landscape.

Project Specifications

• Implementation type: Brownfield (Existing site)
• Robots: 22 R5 Robots
• Workstations (Ports): 4 Ports for picking and replenishment
• Bins: 51,000 Bins
• WMS: Deposco
• Integration Partner: KPI Solutions
• Integrated technology: Kommand AS software, put wall, autobagger