AutoStore Powers Rapid Expansion for Helly Hansen

Source: Element Logic

Helly Hansen, a global leader in sportswear and workwear for outdoor environments, faced significant scalability challenges as it expanded rapidly in the U.S. market. AutoStore, empowered by partner Element Logic, provided the solution. We transformed this Washington-based company into a high-efficiency operation that dramatically reduced order fulfillment times from 2 or 3 days to mere hours. At the same time our solution supports continued growth and maintaining customer satisfaction.

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The Challenge: Grow Fast and Keep Customers Satisfied

As Helly Hansen's popularity surged in the U.S. market, its Sumner, WA warehouse struggled to keep pace with increasing demand:

• Manual, labor-intensive processes hindered efficiency.
• Existing warehouse space lacked the adaptability needed for rapid growth and scalability.
• Customers expected seamless warehouse efficiency and service quality.

The need to seamlessly handle various order types, including direct-to-consumer, e-commerce, and wholesale, added complexity to operations. These challenges were compounded by the need to maintain Helly Hansen's commitment to operational excellence while meeting ambitious growth targets. The brand sought a scalable solution that could enhance distribution capabilities and exceed customer expectations.

The Solution: An Automated Warehouse System

Helly Hansen used AutoStore, implemented by Element Logic, to overhaul its distribution operations. The implementation featured 50,000 Bins, 36 Robots, and 10 CarouselPorts, marking a shift towards unparalleled operational efficiency.

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AutoStore's system operates through a grid-based approach. Goods are stored in stacked Bins within an aluminum framework called the Grid. Robots move across the top of the Grid, retrieving Bins as needed by lifting them to the surface. These Robots then deliver the Bins to designated workstations, where items are picked or replenished. The system optimizes space usage and allows for rapid, precise retrieval, significantly enhancing warehouse efficiency and reducing order fulfillment times. The modular design also ensures easy scalability, making it adaptable to growing operational needs.

AutoStore simplifies the handling of various order types for Helly Hansen— including direct-to-consumer, e-commerce, and complex wholesale — and integrates picking, packing, and shipping into a seamless, unified operation.

Key Benefits: Efficient, Unified, Scalable Operations

AutoStore has transformed Helly Hansen’s warehouse into a highly efficient, adaptable space, maximizing its use without the need for costly expansions.

• Faster orders: Order fulfillment time has reduced from 2 or 3 days to just half a day — an 83% improvement.
• Improved customer satisfaction: Faster delivery times and improved order accuracy have positively impacted the customer experience, reinforcing Helly Hansen's reputation for excellence.
• Scalability is assured: AutoStore's modular design supports Helly Hansen's future growth, allowing for easy expansion as operational needs evolve.
• Simpler order handling: AutoStore simplifies various order types, including direct-to-consumer, e-commerce, and complex wholesale.
• Unified operation: The operation has integrated picking, packing, and shipping.
• Reduced manual effort: Automation has reduced physical demands on warehouse staff and created a more sustainable working environment.

Helly Hansen Sets a New Standard for the Sector

Using AutoStore's technology, Helly Hansen has overcome its immediate challenges and positioned itself for continued success in the competitive sportswear and workwear market. The company can now meet and exceed customer expectations while maintaining the agility to adapt to future market demands. Today, Helly Hansen's Sumner warehouse stands as a testament to the power of innovative automation.

The transition from manual, labor-intensive processes to an automated, efficient system has addressed the critical challenges of rapid growth and the need for adaptable warehouse space. With order fulfillment time slashed, physical work demands reduced, and growth potential taken care of, Helly Hansen’s operational efficiency is at peak.

As Helly Hansen continues to grow and evolve, AutoStore provides a solid foundation for ongoing success. The seamless integration of technology and human expertise has created a warehouse operation that is not just efficient, but also well equipped to face the challenges of tomorrow, setting new standards for efficiency and customer service in the sportswear and workwear industry.

Project Specifications

• Implementation type: Brownfield (existing site)
• Robots: 36 R5 Robots
• Workstations (Ports): 10 CarouselPorts
• Bins: 50,000 Bins
• Warehouse Management System: eManager
• Integration partner: Element Logic