Apparel Supply Smart High-Bay Warehouse: Stacker AS/RS Connects Omni-Channel Fulfillment for Fashion Brands

A domestic omni-channel fashion group covering offline stores, e-commerce and live streaming sales. It carries over ten thousand apparel SKUs with frequent seasonal launches, demanding large pallet storage and fast split-case order delivery.

Project Value

Space Expansion: Storage capacity increased by 2.9x to support annual new product expansion without new warehouse construction
Fulfillment Upgrade: Sorting efficiency raised by 260%, order error rate under 0.02%, 99.9% on-time delivery during big promotions
Cost Optimization: On-site warehouse labor cut by 75%, inventory turnover cycle shortened by 40%, saving 5.2 million RMB in annual operation costs

Project Background

Traditional flat warehouses only reach 30% space utilization with messy size & style management. Slow manual sorting leads to severe order backlogs during promotions, and time-consuming stocktaking fails to support fast new product launches and multi-channel delivery.

Solution

Multi-lane stacker high-bay AS/RS constructed with massive high-density locations to greatly expand storage capacity
Stackers integrated with conveyor lines realize full automation for pallet receiving, storage, sorting and shipping of garments
WMS system interlinks with stackers to manage style/color/size batches, FIFO rules and intelligent order allocation for stores & e-commerce

Project Difficulties

Diverse apparel packaging with varied carton sizes requires stable stacker handling to avoid extrusion damage
Sharp order surges during sales promotions demand stable collaborative operation of multiple stackers under high concurrency
Integration with brand ERP, e-commerce platforms and store distribution systems for real-time omni-channel inventory data sharing