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How Tailored Material Handling Solutions Make Peak Performance Possible
No two businesses are alike, and neither are their supply chain challenges. In today’s world, where consumer expectations grow faster than warehouse footprints, companies need systems as dynamic as the industries they serve. At TGW Logistics, we believe that with the right strategy and tailored material handling solutions, it’s possible to build resilient, scalable, and efficient supply chains—regardless of your unique needs. Whether optimizing warehouse workflows or tackling fluctuating demand, our customized systems integrate cutting-edge tools like conveyor systems and mobile robotics to meet the moment.
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Balancing Flexibility and Stability: Fixed and Mobile Automation in Harmony
Supply chains are rarely static. Peaks in demand, shifting market trends, or even changes in warehouse layouts require systems that can adapt without sacrificing efficiency. Fixed systems have long been the silent heroes of material handling. Fixed automation, like conveyor systems and Automated Storage and Retrieval Systems (ASRS), excels in environments that demand consistency. They move products quickly and reliably through a warehouse, reducing manual handling and improving accuracy.
However, with the rapid development of ecommerce and the adoption of technologies like AI, big data, and the Industrial Internet of Things (IIoT), the role of mobile automation has grown dramatically. Autonomous Mobile Robots (AMRs) and Automatic Guided Vehicles (AGVs) bring agility to logistics, a trend reflected in the market's projected growth to $85.19 billion by 2030.
The balance between fixed and mobile automation often holds the key to operational flexibility. Mobile robots can handle dynamic picking tasks during peak periods, while fixed conveyors ensure steady, high-volume throughput year-round. This combination minimizes bottlenecks, ensures seamless workflows, and redeploys human operators to higher-value tasks, further boosting efficiency.
The addition of automated systems also helps businesses leverage real-time demand data for better decision-making, smarter order fulfillment, and reduced lead times, all of which are crucial in meeting today’s consumer demands. Fixed and mobile automation embody the tailored solutions TGW Logistics delivers, providing the flexibility and scalability needed for businesses to adapt to evolving logistics challenges.
Maximizing ROI: Tailored Solutions Pay Off
Investing in automation is a capital decision—and a strategic one. Tailored solutions ensure that every dollar spent aligns with your operational goals and delivers measurable returns. In fact, businesses that invest in warehouse automation often see a return on investment (ROI) within 3-5 years, with some achieving payback in as little as 18 months.
For many businesses, a combination of leasing and owning automation systems has proven effective. Leasing mobile automation, for instance, can help reduce upfront costs and provide flexibility to adapt during peak seasons, while owning fixed systems ensures long-term control and scalability. This hybrid approach allows companies to maximize both immediate cost savings and long-term financial performance. Leasing can also lead to higher Net Present Value (NPV) and Internal Rate of Return (IRR) than owning outright, making it an attractive option for businesses that balance immediate needs with future growth goals.
Empowering Employees: Automation That Works With People, Not Instead of Them
While automation often steals the spotlight, TGW Logistics never forgets the people behind the systems. Human-centric design is at the core of every tailored solution we create. Integrating ergonomic features and collaborative automation can make a real difference in employees’ day-to-day. In one case, a manufacturer struggling with repetitive strain injuries among its workforce turned to us for help. The solution combined ergonomic picking stations with conveyors to reduce manual lifting and repetitive motions, which reduced workplace injuries and boosted employee satisfaction and morale. Automation doesn’t replace people—it empowers them to work smarter, not harder.
Real-World Success: Tailored Solutions in Action
Every logistics challenge comes with its complexities. Our tailored solutions tackle these challenges head-on, combining advanced technology with strategic design to create systems that deliver measurable impact. With a focus on adaptability and precision, TGW Logistics transforms how businesses approach supply chain management. From integrating automation for seamless fulfillment to optimizing returns processing, we help clients reimagine what’s possible. The following success stories from Engelbert Strauss and Victoria’s Secret & Co. illustrate how our innovative solutions have driven operational excellence for two industry leaders.
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Engelbert Strauss – A Fully Integrated CI Factory
When scaling a business, there’s no one-size-fits-all solution—especially for a company like Engelbert Strauss, a global leader in workwear. With orders ranging from small split-case purchases to large bulk shipments, they needed a logistics system as versatile as their customer base. TGW Logistics rose to the challenge with a tailored approach, designing and implementing the automation within the CI Factory in Schlüchtern, Germany—a fully integrated facility that combines production and fulfillment under one roof.
The Solution:
- FlashPick Order Fulfillment: This goods-to-person system operates with incredible speed and precision, processing up to 1,000 pieces per workstation per hour. The system can handle 4,000 cartons per hour during peak times, enabling rapid order fulfillment.
- Automated Returns Management: We implemented an automated inspection, repackaging, and storage system with one million storage locations, drastically reducing the time it takes for returned items to be ready for re-picking.
- Omni Channel Excellence: By integrating automation, Engelbert Strauss achieved seamless coordination across all order types, including ecommerce, retail, and wholesale.
The Results:
- Scalability: The automated shuttle system and mini-load warehouse allow the company to adapt effortlessly to growing demand.
- Customer Satisfaction: Enhanced workflows improved order accuracy and packing processes, resulting in higher customer satisfaction.
- Efficiency Redefined: Combining production and fulfillment ensures rapid order processing and delivery, even during peak periods.
Victoria’s Secret & Co. – A High-Performance Fulfillment Hub
For a brand like Victoria’s Secret & Co., known for its iconic collections and unparalleled customer service, delivering on customer expectations requires speed, precision, and adaptability. Facing a rapidly growing ecommerce business, Victoria’s Secret turned to us for a tailored solution that could balance flexibility with performance. The result? A state-of-the-art automated fulfillment hub in Columbus, Ohio, designed to meet the unique demands of one of the world’s largest intimate apparel brands.
The Solution:
- FlashPick Technology: This high-performance system allows Victoria’s Secret to handle up to 640,000 picks daily, making it one of North America's most efficient fulfillment centers.
- Integrated Warehouse Software: Our modular software manages everything from storage sequencing to picking flow control, optimizing the entire order fulfillment process.
- Pick-to-Light Manual Order Picking: The facility added our pick-to-light manual order picking area—an uncommon addition for FlashPick. It’s primarily used during peak days for a cost-effective, efficient way to scale picking power without needing permanent picking stations that might stay underutilized for most of the year.
The Results:
- Unparalleled Capacity: The hub can process up to 225,000 orders daily, ensuring rapid delivery and meeting the high expectations of Victoria’s Secret’s customers.
- Operational Excellence: The automated system guarantees order accuracy, reduces lead times, and supports scalable operations during peak seasons.
- A New Standard in Flexibility: With its combination of advanced robotics and manual workflows, the fulfillment center adapts seamlessly to fluctuations in order volume.
Tailored Solutions Make Anything Possible
Our tailored solutions are built on flexibility, scalability, and innovation. Whether optimizing workflows, boosting efficiency, or integrating cutting-edge technology, TGW Logistics proves anything possible with a customized approach—including contributing to businesses’ overall efficiency goals. Our energy-efficient systems reduce waste and minimize environmental impact while optimizing transportation routes to cut emissions.
Ready to transform your supply chain? Download our eBook to learn more, or contact us for a consultation today. Together, we’ll build a system that’s tailored to you.