POSTNL AUTOMATES E-FULFILLMENT WITH ASTRO WMS® AND PICK-TO-LIGHT 

PostNL has implemented one of the largest automated warehouses (AutoStore) in Benelux. The fulfillment center in Houten provides all the logistical services small and medium-sized webshops need to grow their online business. The order picking process uses Astro WMS® from Consafe Logistics and is supported by an integrated pick-to-light solution.  

Challenge

PostNL provides all the logistics for its customers: from maintaining their stocks, order picking, and packaging to delivery of all orders. Before the automated solution, several pickers would pick for just 5 customers, walking more than 5 kilometers daily to collect order lines. The company wanted to increase the order picking rate and improve total efficiency.

Solution 

Warehouse Management System 

The company started the selection of a new WMS for its fulfillment center in early 2014. They chose Astro WMS® due to its extensive standard functionality, flexible configurability, and scalability. The system’s user-friendliness and the fact that Astro WMS® can be used via the cloud also impacted the decision. 

Automation 

PostNL implemented AutoStore and pick-to-light in phases and continues looking for further improvement opportunities.  

The distribution center in Houten:  

• Covers 17,000 square meters
• Uses 42 robots to transport 21,000 bins of goods to 6 pick stations
• Combines 10 packing stations and an integrated ‘pick-to-light’ solution, processing online orders with 100% accuracy
•  Has a capacity of around 1,200 order lines per hour
   

Results

Since adding automation to the warehouse, PostNL has achieved the following: 

• Products are brought to the right picker by robots 
• Order picking rate increased tenfold 
• An employee can process orders from 50 to 60 customers 
• The total efficiency tripled 
• Order processing is more traceable for customers 
• 100% accuracy by weighing and photographing all products before they are packaged 

In addition, about 30% of all orders are currently ordered in the evening and are ready for shipment within half an hour to an hour. 

Astro WMS® central to operations 

Astro WMS® is central to all logistical systems at PostNL. All incoming orders are automatically inputted based on an existing order management system. Robots and pick stations work after Astro WMS® calculates the most efficient pick routes. In addition, based on product dimensions and weight, Astro WMS® calculates the most suitable packaging to send less air and volume.