Desigual
Viladecans Distribution Center
7,980
Storage Locations
30,000 Units/day
Daily Delivery Efficiency
650 Cartons/hour
Throughput
3-4 Times
Improved Warehouse Efficiency
60-80%
Lower Operational Costs
99.99%
Picking Accuracy
In a fast-moving industry like fashion, adaptability and operational efficiency are key to sustaining growth. Desigual is a globally recognized fashion brand founded in 1984. The company has long relied on advanced logistics to maintain its competitive edge.
As part of its strategic evolution, Desigual started collaborating with Hai Robotics and an integrator partner. Their goal has been centralizing storage and boosting efficiency at their warehouse in Viladecans, Spain. This project was designed to consolidate operations, which had previously been split between two warehouses. This way, the warehouse could deliver greater efficiency, scalability, and flexibility in response to fluctuating market demands.
- Centralized Operations: Desigual needed to consolidate its warehouse activities at the Viladecans Distribution Center (DC), transitioning away from traditional pallet rack systems to a fully automated, integrated solution. This shift was critical to enhance operational efficiency and reduce logistical redundancies across multiple facilities.
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Storage Density and Space Utilization: Desigual was operating within a constrained warehouse layout, with a ceiling height of only 5.3m. Therefore, the company faced challenges in maximizing storage density, while accommodating a wide range of product SKUs.
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Order Assembly Precision: The fashion industry needs careful sorting by collection and size. This ensures store deliveries are ready for display right away. Desigual needed an automation system that met these high standards. This was especially important for re-orders during the season and online purchases.
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Labor Efficiency and Costs: Desigual faced rising labor costs, workforce shortages, and needed extensive staff training. Therefore, a reliable automated system was essential for reducing manual handling and improving throughput.
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Scalability and Future-Readiness: Desigual needed a new system. This system had to meet current needs and allow for future growth. It also needed to adapt to changes in customer behavior, like the rise of omnichannel retailing.
- Warehouse area: 1,334㎡ with a 5.3m clear height
- Robots: 25 HaiPick A42-LN-E4 with 4.9m picking height
- Workstations: 4 Double In & Out Conveyor Workstations (each with two put walls), 1 HaiPort workstation
- Charging Stations: 8 HaiCharger units
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Centralized Storage Integration
Hai Robotics set up a HaiPick-based goods-to-person system on the third floor of the Viladecans warehouse, which had previously been underutilized. Even with a height limit of 5.3 meters, it was designed to hold 7,980 storage locations. The solution also enables future growth.
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High-Density Storage & Picking Solution
HaiPick Autonomous Case-handling Mobile Robots (ACRs): Deployed 25 HaiPick A42 robots capable of handling 8 cartons simultaneously. The result was a stable and efficient picking process with a maximum throughput of 30,000 units/day.
HaiPort-powered Workstations: Installed 4 Double In & Out Conveyor Workstations and 1 HaiPort workstations, enabling fast and accurate carton transfers to lower floors for final processing.
Store-Friendly Order Sequencing: The solution ensures store-friendly order fulfillment by sequencing products within the warehouse. Items are pre-sorted into order bins based on SKU type. Store staff can then quickly unbox and directly place products on shelves in the correct order. This system streamlines in-store operations and improves efficiency.
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Scalability & Redundancy
Future-Ready Design: The modular setup allows Desigual to easily expand. The company can add more rack lines and ACRs as business demands grow.
Operational Continuity: Even during maintenance or service interventions, the remaining robots ensure continuous operations, providing a highly reliable system.
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Advanced Software Integration
Hai Robotics connected the newly implemented HaiPick system to Desigual’s existing WAMAS warehouse management system. The solution ensured seamless operation and improved order handling efficiency. This integration was crucial in supporting Desigual’s shift towards increased B2B operations.
This saves us a lot of time and money! It is very easy to manage this type of solution, both in terms of implementation as well as use by staff. Our teams’ experience with the integrator and Hai Robotics has been consistently positive.
This saves us a lot of time and money! It is very easy to manage this type of solution, both in terms of implementation as well as use by staff. Our teams’ experience with the integrator and Hai Robotics has been consistently positive.
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