Consumer Goods Logistics

Leroy Merlin’s Consumer Goods Logistics Evolution

Paris, France

Advanced Automation and Warehouse Ergonomics

Leroy Merlin, the leader in France's DIY and interior design market, faced growing demand from its stores and direct customers. With a complex product range and the need for efficient order fulfillment, Leroy Merlin partnered with TGW Logistics to build a new fulfillment center near Paris. Through our advanced automation and warehouse ergonomics, what once seemed like logistical roadblocks became streamlined possibilities.

Turning Challenges into Opportunities: The Journey Begins

Leroy Merlin recognized that their existing fulfillment processes couldn’t keep up with the pace of modern consumer goods logistics:

Labor shortages and physically demanding manual processes were leading to inefficiencies.
The variety and complexity of heavy, cumbersome products created an unsustainable workload for warehouse employees.
The company needed to improve delivery speed, reduce operational costs, and ensure the ergonomic safety of employees' workplaces.

TGW Logistics’ tailored approach to automation and supply chain optimization would address all these needs head-on.

Making the Impossible Possible: FlashPick and KingDrive at Work

At the core of this transformation is TGW Logistics’ FlashPick system. Leroy Merlin's new nine-aisle warehouse has over 170 Stingray shuttles and 80,000 storage locations - handling up to 70,000 order lines daily. FlashPick enables the seamless processing of a wide range of products, including oversized items up to 800 x 600 mm, so that the warehouse can handle orders of all sizes.

Energy-efficient KingDrive conveyors interconnect the various functional areas, providing a smooth flow between storage and picking stations for efficient consumer goods logistics. Six error-free, 1:1 high-performance picking workstations (one order tote to one storage tote) ensure retail order fulfillment quickly and accurately. Our Warehouse Control System (WCS) oversees the entire operation, from planning to monitoring, for optimal performance.

Before the new system, manual palletizing was difficult due to the variety of product sizes - particularly heavy items. Combining automated goods-to-person picking and automated guided vehicles (AGVs) streamlined the process so the team could handle even the most challenging products efficiently.

Automation and Ergonomics: A Win for Employees

The automated picking area also includes partially automated depalletizing stations, with automatic replenishment from goods receiving and the warehouse via AGVs. Our focus on ergonomics extended to every manual workstation, using the RULA method to analyze and optimize each, reducing the risk of musculoskeletal injuries. Leroy Merlin chose the semi-automated SlotStax palletizing solution, supplemented with a robot for handling heavy and cumbersome items from storage totes. The flexibility of the SlotStax solution was essential, given the variety of products that needed to be palletized for different stores.

This new setup rendered arduous manual tasks obsolete, simplified the depalletizing process, and allowed Leroy Merlin to deliver well-structured pallets to stores without product breakage. The improvements in ergonomics and automation made working conditions safer and more attractive, allowing Leroy Merlin to attract more female employees—a significant milestone in a traditionally male-dominated field. By reducing the physical strain on workers, the company was also able to combat the labor shortage and retain a diverse, highly productive workforce.

The Results: When the Possible Becomes Reality

Balancing speed, cost efficiency, and employee well-being became the new normal for Leroy Merlin. The transformation of Leroy Merlin’s fulfillment center solved supply chain logistics challenges and revolutionized operations, most evident in these areas of impact:

Reduced Lead Times

Optimized material flows and high-performance picking stations slashed lead times and facilitated faster customer deliveries.

Lower Operational Costs

Automation drove cost savings, making it possible to run the fulfillment center more efficiently without sacrificing performance.

Improved Employee Well-Being

Ergonomically designed workstations minimized injury risk, proving that employee health and productivity can go hand in hand.

TGW Logistics’ FlashPick system addressed Leroy Merlin’s immediate needs and future-proofed their operations. The fulfillment center is now equipped to handle growing demands, from single-item orders to bulk shipments for stores. With the support of TGW Logistics’s Lifetime Services maintenance contract, Leroy Merlin can rely on continued high system availability, enabling them to control operational costs and ensure consistent performance for years to come. This project didn’t go unnoticed. In 2023, the fulfillment center received the prestigious "Grand Prix des Rois de la Supply Chain" award in recognition of its groundbreaking approach to logistics and supply chain optimization.

It’s Possible with TGW Logistics: Let’s Make Your Vision Happen

Built on a shared belief that no challenge is too big, Leroy Merlin and TGW Logistics transformed logistical complexity into seamless consumer goods logistics, created a better employee environment, and set new standards for fulfillment centers across the industry. With our innovative solutions and expertise, what once seemed impossible is now within reach for businesses worldwide.

Whether you're looking to optimize your supply chain, reduce costs, or improve employee well-being, TGW Logistics can help you make it possible.