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30,000 SKUs stored in the central distribution centre
13,000 picked items per day planned
189 Rexel branches supported across the UK
Introduction
Rexel UK, part of the Rexel Group, is a leading electrical distributor and solutions provider in the United Kingdom. The company operates under two brands, Rexel and Denmans, and has 280 branches and 15 logistics hubs in the UK market.
In a strategic move to elevate customer service across the country, the company revolutionized its logistics operations by investing in a new central distribution centre in Aylesbury. The project involved adopting a state-of-the-art warehouse management system (WMS) from Consafe Logistics and implementing an AutoStore solution.
Challenge
At the heart of Rexel UK’s operations lies a robust customer focus, driven by the ambition to offer superior service availability. The company wanted to enhance its logistics operations with the following goals:
- To centralize digital orders across the country to ensure that 30,000 products were available for next-day delivery. Previously, these products were picked across the whole network.
- To offer extended cut-off times for customers placing orders online.
- To implement the one order - one shipment policy, ensuring customers receive their orders in one parcel instead of multiple ones.
- To use the company’s own fleet for delivery, enhancing the customer experience from order placement to the final mile.
- To operate more sustainably by optimizing logistics to reduce the carbon footprint and by embracing electric vehicles for city deliveries, e.g., in the London area.
Solution
To transition to a centralized logistics approach, the electrical distributor invested in a new 17,300 sqm distribution centre in Aylesbury, a modern warehouse management system, Astro WMS®, from Consafe Logistics, and a cutting-edge AutoStore solution.
The facility was designed with sustainability at its core, featuring solar panels on the roof to enable carbon-neutral operations. The architecture incorporates high ceilings and expansive windows, filling the space with more natural light, thereby not only reducing energy consumption but also improving the work environment for warehouse staff.
Rexel UK’s decision to partner with Consafe Logistics was influenced by successful collaborations with other Rexel subsidiaries in Europe, notably in Germany and the Netherlands. Internal best practices included a proven model of a similar integration setup between the AutoStore solution and Astro WMS®. The system could also handle the administration of cutting cables, a unique requirement in the electrical sector. In addition, Astro WMS® provides a user-friendly, configurable interface. This interface plays a key role in simplifying operators' work. By tailoring the solution to their needs, it boosts day-to-day efficiency and productivity, leading to greater employee satisfaction.
The project implementation began in early 2022. The first phase introduced manual picking in the new warehouse. AutoStore became part of operations in the summer of 2023, and the rollout for 189 branches concluded by May 2024. Throughout the entire process, Consafe Logistics’ team worked closely with the customer, ensuring the delivery of comprehensive solutions with a hands-on approach.
Today, 70% of order picking at the new distribution centre is automated, while 30% is manual. There are 24,000 AutoStore bins, 8 picking ports, and 3 ports for receiving inbound stock. Astro WMS® is responsible for orchestrating all processes from inbound, through putaway, picking, packing, to dispatching orders.
Key results include:
- 30,000 SKUs stored in the central distribution centre
- 13,000 picked items per day planned
- Support for 189 Rexel branches across the UK