All Sport Maximizes Warehouse Efficiency with Modula Vertical Lift Modules

All Sport Case Study Summary

All Sport, a leading distributor in the sports and lifestyle industry, was established in the 1970s in Belgium and has since expanded internationally. The company focuses on making brands successful in the European market by prioritizing customer needs and closely collaborating with brands. To improve warehouse efficiency, All Sport sought to maximize space usage in their new warehouse. By installing six Modula Vertical Lift Modules (VLMs), the company fully utilized the height of its new warehouse, achieving a five-fold increase in storage capacity and significantly improving order picking speed. The implementation of Modula’s WMS software also streamlined staff deployment, ensuring All Sport is well-prepared to manage high demand during busy periods.

The Challenge

All Sport faced three main challenges: improving employee productivity, optimizing storage space, and ensuring they could scale staffing levels quickly to handle peak demand, especially during times like Black Friday. The old system required a large amount of floor space, and order picking was slow, limiting the company’s ability to meet growing demand efficiently.

The Solution

All Sport worked with Modula to create a solution tailored to its needs. The company installed six Modula Vertical Lift Modules, each with a work opening on the second floor. These units were integrated with a Put to Light system and conveyor system, which transports totes via a bin elevator from the second to the ground floor. Once on the ground floor, the totes moved through the packing section and onto the sorting area, which featured seven exits.

The implementation of Modula’s system had a major impact on productivity, increasing order picks per hour per person from 40 to 150. Additionally, by utilizing the full height of the warehouse, All Sport achieved a five-fold increase in storage capacity. The intuitive Modula software also made it easy to scale staffing quickly, with a short learning curve for new employees.

Key Features of the All Sport Case Study:

• Increased Productivity: With the new system, All Sport increased order picks per hour per person from 40 to 150.
• Space Optimization: By fully utilizing the warehouse height, the company achieved a five-fold increase in storage capacity.
• Efficient Scaling: The intuitive Modula software allows for quick deployment of staff, ensuring that All Sport can handle peak periods with ease.
• Advanced Integration: The Modula system is seamlessly integrated with Put to Light and conveyor systems, improving overall efficiency.