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May 11, 2021 at 5:45 PMOn an area of 155,000 m², Levi Strauss & Co. is building one of the largest logistics hubs in Europe for fashion items and accessories in Wulfen (Dorsten/Münsterland). The denim leader is consolidating its logistics processes at a central location. TGW will deliver the highly automated intralogistics system for omni-channel operations by November 2023.
(Marchtrenk) On a site of nearly 155,000 m², Levi Strauss & Co. is consolidating its European logistics in Dorsten. The goal is to respond more quickly and efficiently to market needs, shorten delivery times, and accelerate growth across all sales channels. The new location supports Levi Strauss & Co. in advancing sustainability, flexibility, and digitalization of the global supply chain. “We are pleased to have commissioned the intralogistics specialist TGW Logistics Group to set up our MHE system,” says Torsten Mueller, who is responsible for logistics and the project at Levi Strauss & Co. in Europe.
Highly Automated Logistics Hub
The special feature of the logistics hub is the intelligent, highly automated goods-to-person system: TGW FlashPick® has been developed to flexibly handle unpredictable and fluctuating order structures. Should the order share between sales channels (stores, online, and wholesale) shift or the order structure change, the system continues to meet the new requirements efficiently and supports the growth of the denim leader.
Average Lead Time of Only Ten Minutes
On peak days, up to 350,000 items can be shipped. The lead time from order start to shipping-ready package averages only about ten minutes. The project is divided into two phases: In the first phase until 2023, a throughput capacity of up to 33 million items per year will be achieved. This value will increase in a second step to 55 million – through the expansion of storage capacity and additional picking workstations.
TGW Warehouse Software as Central Interface
The centerpiece of the facility is the combination of a five-aisle shuttle system and an automatic small parts warehouse (AKL) with 830,000 storage locations. Orders are picked at ten picking workstations in the PickCenter, and an eight-kilometer-long network of energy-efficient KingDrive® conveyor technology connects the areas.
The TGW Warehouse Software supports Levi Strauss & Co. in managing the high demands of omni-channel operations and is an integral part of the solution: it takes over planning, monitoring, and optimizing all intralogistics processes.
Sustainability in Focus
To use resources efficiently, up to 70 percent of the delivered goods cartons are reused for shipping. An innovative robotics solution from TGW takes care of the automatic repacking from cartons into containers. Additionally, Levi Strauss & Co. refrains from using plastic polybags for shipping – instead, they pick directly into cartons or paper bags.
Fast Lead Times, Higher Service Level
“We are very pleased that we were able to convince a logistics-experienced customer like Levi Strauss & Co. of our automation expertise,” emphasizes Johann Steinkellner, CEO Central Europe at TGW. “Thanks to FlashPick®, e-commerce, wholesale, and retail can be efficiently linked together. For companies with an omni-channel business model like Levi Strauss & Co., this is a decisive competitive advantage.”
About Levi’s®:
The Levi’s® brand is the epitome of classic American style and authentic coolness. Since Levi Strauss invented jeans in California in 1873, Levi’s® jeans have become some of the most recognized garments in the world. With pioneering and innovative spirit that is unmatched in the apparel industry, Levi’s® continues to develop its brand portfolio. The unique jeanswear and accessories offering is available in more than 110 countries, allowing people around the world to express their personal style.
