Zeeman has radically modernised its logistics operation in Alphen aan de Rijn. The result is a largely automated operation, where incoming goods are quickly and efficiently distributed towards shops using a combination of a shuttle and pick-to-light system. By storing the boxes in the right order, Zeeman is able to optimise the filling level of the roll cages and thus also the loading level of the trucks. As system integrator, Inther Group signed up for the total solution.
In 2018, Zeeman embarked on an ambitious journey to modernise its existing logistics operation. The retailer, known for its large-scale shop network in Europe, wanted to say goodbye to its outdated, manual sorting system and switch to a future-proof, automated concept that could grow seamlessly with the organisation's retail ambitions. Together with Inther, a total solution was developed that focused on efficiency, ergonomics and scalability.
Important starting point was to improve roll container fill rates and truck load factors, increase flexibility in SKU supply, and enable just-in-time delivery to the more than 1,400 shops in Europe. In addition, increasing ergonomics and sustainability in the warehouse was an objective. An added complexity was that all this took place in a brownfield situation: the existing building in Alphen aan den Rijn remained operational throughout the conversion.
Complete redesign
Zeeman opted for a total system transformation. They wanted to not just renew their logistics operation, but completely rethink it: new processes, a new system design, new technologies as well as cooperation with multiple integration partners. "It is a complete redesign of all processes, systems and way of working. Moving away from a 25-year-old sorter operation to a state-of-art shuttle system, and that in the same building, has challenged us to the max," says Bas Hoekstra, director supply chain at Zeeman.
Inther had the task of bringing it all together. This system integrator was thus given responsibility not only for the design, system selection, integration and realisation of the chosen solution, but above all for connecting all the links in the chain. Martijn Herder, CEO of Inther Group: "We really made a design together with Zeeman in the preliminary phase, with clear starting points. On that basis, the entire system was designed and validated through simulations."
Modular concept with AI
To realise these ambitions, a fully automated system concept was chosen, based on realistic data analysis and a modular approach. An innovative combination of existing technologies, applied in a way that perfectly suits Zeeman's high volumes and specific distribution challenges.
The core of the system is a six-aisle shuttle storage system, where each box can be accessed individually. Thanks to different storage patterns, a wide variety of box sizes can be stored directly. As a result, SKU limits are a thing of the past and each order line can be precisely positioned for optimal container filling. This provides maximum flexibility and allows orders to be optimised at box level for loading and shipping.
Different flows
The system is fully integrated with both Inther ILC and external software. The result is a flexible shuttle system that allows Zeeman to efficiently manage all inbound and outbound goods flows:
- Cross-dock flow: OEM boxes enter the system directly from the container.
- Stock items: depalletised, buffered and processed via shuttle.
- Order picking goods: picked via pick-to-light and then directly to the shuttle.
All boxes - picked or not - pass through the shuttle system. This forms the central backbone of the operation. These boxes - regardless of their origin - are automatically stored in the shuttle and intelligently ordered (re-shuffling) to be ready at the right time in the right order and stacked in roll containers. This uses smart software and algorithm-assisted loading. This is essential for optimal filling. After all, every cubic centimetre counts.
Continuous optimisation
Inther Group not only supervised the design, realisation and implementation of the system, but also took a leading role in the service and maintenance process. From the very beginning, specialists from Inther's service department were involved and worked closely with Zeeman's technical department. Together, maintenance plans were drawn up, spare parts were tested and SLAs were aligned with the reality of the operation.
The system is now running stably, and further refinements are being made daily based on real-time data. The good cooperation with Zeeman is also reflected in joint improvement projects, which benefit both Zeeman and Inther, such as data science dashboarding, predictive maintenance and fill rate optimisation.
Scalable and future-proof
The project had a lead time of several years, with phases of analysis, design validation, realisation and optimisation. Upon completion, Zeeman has a system that is fully scalable, independent of article structures, and can operate without SKU limits. Tens of thousands of boxes are processed daily to supply more than 1,400 shops. Focusing on flexibility, speed and fill rate optimisation, the entire operation - from receiving to shipping - is future-proof.
Herder: "Although the combination of techniques is new, the concept builds on Inther's experience from previous projects. What makes Zeeman unique is the scale and the way everything is integrated. The combination of automated storage, advanced picking methods, smart sorting and the use of AI for depalletising is rarely seen in the retail sector in this way." André Peppelman, supply chain development manager at Zeeman added: "With so many different supplying parties, Inther has performed its integration role well, a reliable partner that makes the components come together into one working whole."
Results:
- No more SKU limits: each box can be controlled individually
- Optimal container loading through sequence-based feeding
- Flexibility in flow management: direct crossdock, stock, or orderpick
- Integrated AI and pattern recognition for depalletising
- Less physical strain and higher ergonomics
Technical specifications:
- Shuttle aisles: 6
- Storage capacity: 60,000 to 100,000 boxes
- Sorters: 2 shoe sorters
- Channelizers: 2 units
- pick-to-light workstations: 20
- pick-to-light locations: 960
- Automatic loading: 6 Elten stack stations
- Type of load carrier: roll containers
Project details:
- Objectives: increase load factor, improve availability, optimise ergonomics
- Solution type: fully integrated warehouse system
- Specifics: implementation during ongoing operation (no greenfield), limited dock capacity
- Technologies: shuttle, (de-)palletisers, pick-to-light, algorithm-assisted loading, box erectors, roll container loading, visualisation and control, conveyors, AMRs, WMS integration
- Partners: Manhattan, DGS, TGW, CICT, Elten, Lantech
