Managing complex picking processes

The new system will enhance performance, flexibility, safety, and efficiency across the warehouse. BlueStar’s primary distribution centre in Eindhoven specialises in handling a diverse range of products, from compact barcode scanners to large-scale digital displays. This makes warehouse optimisation, precise inventory management and efficient logistics crucial to its operations.

Before partnering with Exotec, BlueStar experienced multiple challenges in its pursuit of optimised operations:

Complex picking processes: The Eindhoven warehouse had several distinct picking zones. Orders often required multiple touches, with some products moving between zones as many as five times before final consolidation.

Labour shortages: Following the Covid-19 pandemic, the availability and cost of labour became critical concerns, pushing BlueStar to seek automation capabilities that reduced dependency on manual processes.

Scalability and flexibility: With a product catalogue ranging from small consumer devices to large industrial screens, the company lacked a system capable of adapting to various product sizes and demand fluctuations.

Sustainability goals: BlueStar wanted to minimise the environmental impact of its operations while enhancing overall efficiency.

Following the implementation of Skypod, BlueStar has experienced significant improvements in distribution efficiency and has seen a range of operational benefits. These include the consolidation of picking zones, enhanced inventory accuracy, minimised manual errors and adaptable storage configurations to accommodate a variety of product sizes. This has reduced unnecessary movement and training requirements for human operators while making the facility safer and more efficient overall.

BlueStar EMEA chief operating officer Manel Baranera, says: “Our goal is to stay ahead in a highly competitive market by providing reliable and fast service. The introduction of Exotec’s Skypod system was a significant step in achieving this vision.

“We needed a system that addressed our operational inefficiencies and aligned with our sustainability strategy. Exotec’s solution stood out, decreasing our energy consumption compared to traditional systems and optimising our use of resources, aligning with our commitment to environmental stewardship.

“This collaboration marks the beginning of a long-term partnership with Exotec. The flexibility and scalability of the Skypod system align perfectly with our growth objectives.”

Romain Moulin, CEO and co-founder of Exotec adds: “Throughout our partnership with BlueStar, Skypod has reduced order processing time by streamlining picking operations, optimised warehouse space usage with vertical storage, and decreased the average number of touches per order, enhancing speed and accuracy. Our intuitive system design has also lowered physical strain on operators by automating repetitive tasks and improving workforce dynamics.”

For more information, visit www.exotec.com

+33-9 72 58 56 34