Consumer Goods Logistics

It’s Possible: How TGW Logistics Brought Warehouse Automation to Musikhaus Thomann

Treppendorf, Germany

Expansion of Distribution Center

Musikhaus Thomann, a family-owned music retailer founded in 1954, is one of the largest online music dealers in the world. Known for supplying more than 12 million customers globally, Thomann needed to expand its existing distribution center in Treppendorf, Germany, to meet growing demands. With TGW Logistics’ cutting-edge technology and warehouse automation solutions, an ambitious project became a reality—proving that with the right partnership, anything is possible.

Challenges: Scaling for Global Efficiency Without Disruption

By 2018, Thomann’s growing volume required operational adjustments. With up to 28,000 shipments on peak days and 15,000 shipments on average, keeping up was a struggle—let alone getting ahead. Our initial analysis revealed several priority fixes:

Thomann needed to increase its shipment capacity by 50% to meet rising demand.
Order fulfillment time had to be reduced below the current 56 minutes.
The expansion needed to occur without disrupting daily operations, allowing Thomann to continue fulfilling orders while the new system was implemented.
The new, automated fulfillment center had to integrate smoothly with the existing system without causing operational downtime.

Solution and Material Flow: Streamlining for Success

TGW Logistics’ warehouse automation solutions proved to be the key to Thomann's facility expansion. The upgrade featured an automated pallet storage area with 18,000 positions and automated mini-load aisles with 70,000 tote storage positions. These storage and retrieval systems ensured a fast and continuous supply of SKUs to order-picking workstations.

Goods Receipt and Storage

When goods are received, the system routes them to the automated pallet or mini-load aisles for long-term storage. Once needed for replenishment, they move seamlessly to an automated shuttle warehouse with 110,000 storage positions, allowing for efficient inventory management and preparation for order picking.

Order Picking

TGW Logistics implemented a multi-faceted picking system based on product size. Large goods, such as drums, are handled through a picking area for palletized items. Large cartons, like guitars, are automatically retrieved and routed directly to packaging or shipping. A fully automatic full case picking system allows goods to move from storage to shipping without manual handling. Small parts, such as guitar picks, are delivered to goods-to-person workstations, ensuring precise and efficient picking for each order.

Packing and Shipping

After picking, items from various warehouse areas are consolidated for final packaging. Orders are prepared for shipment based on the type of transport: courier, express, or counter pickup. Automated conveyor connection systems make even local counter pickups faster, ensuring Thomann’s customers receive their orders with minimal delays.

Achieving Warehouse Automation with TGW Logistics

Through this retrofit expansion, Thomann achieved several major milestones that would have been difficult without TGW Logistics’ innovative solutions, highlighting how it’s more than possible to make bold operational changes without disrupting day-to-day activities.

Expansion During Ongoing Operations
Business continuity was non-negotiable for a company that ships more than 15,000 packages daily. TGW Logistics implemented the new system with zero impact on ongoing operations so Thomann could continue to meet its customer delivery commitments even as integration occurred.
Shorter Lead Times
Thanks to TGW Logistics’ warehouse automation, Thomann now fulfills orders in 28 minutes—half the time it took previously—making it possible to deliver products faster and more efficiently than ever before.
Optimized Resource Allocation
The high degree of automation has allowed Thomann to use its resources better. By automating routine processes like picking, packing, and inventory management, the company can operate with fewer manual interventions while increasing accuracy and without proportionally increasing staff.