PRIOR TO the partnership, Renault Group struggled to efficiently manage the delivery and distribution of replacement vehicle parts in Europe. Its system was fragmented, and its warehouses were organised by part types rather than by geographic regions or markets.

As part of a significant overhaul of its operations, Renault Group fully reorganised its spare parts warehouses. This involved closing its older Cergy site to make way for a new facility in Puiseux dedicated to serving European and international markets, and the specialisation of the Flins-sur-Seine warehouse to focus on heavy and bulky parts.

Exotec was called upon to help transform and modernise Renault Group’s Villeroy warehouse. This meant installing Exotec’s Skypod system, which hosts 167 Skypod robots, 14 picking stations, two replenishment stations and 67,000 storage bins, processing 4,130 bins an hour with a rack height of 10.8 metres – enabling the storage and picking of over 1.6 million items.

Improvements include:

• Customer service satisfaction rate now exceeds 99.7%, demonstrating a high standard of reliability.
• The ability to dispatch all parts ordered up to 5:30 PM for next-day delivery by 8:00 AM, ensuring swift and timely fulfilment.
• Consolidating over 80% of French business into a single warehouse, significantly reducing order processing times and streamlining logistics.
• Renault Group has integrated over 15,000 SKUs, with a long-term target of 20,000, ensuring a broad and diverse selection of available parts.
• A productivity improvement within the ReVA perimeter by a factor of 4, aiming to handle 20,000 order lines per day.
• Stabilised and reduced reliance on temporary staff, resulting in a more consistent and reliable workforce.
• Integration of a range of specialised machines in tandem with the Skypod system, including two carton forming machines, two closing machines, three packing list printers, two RFID shipping label printers, a wrapping machine, and 30 ergonomic grippers, enhancing operational efficiency.
• Merged dealer label printers with Exotec picking stations to improve inventory traceability and stock management.
• Incorporated a rubbish collection system directly into the injection stations, optimising waste management processes and maintaining a clean and orderly workspace.