John Lewis

With online sales making up around 60% of total turnover, John Lewis sought to expand its warehouse capabilities to support increasing demand. The acquisition of the Fenny Lock facility in Milton Keynes presented an opportunity to enhance efficiency, improve fulfillment speed, and implement a scalable, high-volume automation solution that could seamlessly integrate with existing operations while allowing for future growth.

To maximize the potential of this new site, JL focused on streamlining operations through automation, integrating advanced technologies with existing infrastructure, and ensuring compliance with stringent safety standards. Through robust engineering, rigorous testing, and close collaboration, these objectives were successfully achieved—strengthening JL’s logistics network and setting a new benchmark for efficiency and scalability.

HaiPick A42T: Designed for high-density storage, these robots can reach up to 10m, handle various case sizes, and achieve an impressive picking accuracy of 99.99%, ensuring flexibility and reliability.

HaiPort Buffer Stations: Configured with 6 outbound and one inbound station, HaiPorts enable rapid multi-case handling, loading up to 8 cases in 3 seconds and unloading in 5 seconds. The system achieves a throughput of 1,500 totes per hour across 9 workstations, with an additional standalone station supporting 400 totes per hour.

Conveyor-based Inbound Station: Streamlines decanting and replenishment processes, ensuring high-speed inbound operations.

HaiQ System Integration: The ESS module seamlessly connects with Logistex’s WMS, ensuring smooth coordination of tasks and optimized operations.

Enhanced Safety Features: Custom safety systems include interlocking mechanisms and fire sprinklers. Robots continue operating at a reduced speed of 0.3m/s when interlock gates are opened, maintaining both safety and efficiency.

The implementation of Hai Robotics’ automation solution at John Lewis’ Fenny Lock warehouse delivered transformative results across key performance areas:

1. Increased Storage Density: By utilizing 10m-high shelving and vertical space more effectively, storage capacity increased by 300%, enabling JL to store significantly more products within the same footprint.
2. Enhanced Throughput: The integration of HaiPort buffer stations allowed for faster order processing, achieving a maximum throughput of 1500 totes per hour, which significantly reduced lead times.
3. Labor Efficiency: Automation reduced reliance on manual handling, cutting labor costs and minimizing errors, which further improved operational efficiency.
4. Improved Accuracy: The system achieved a 99.99% order accuracy rate, ensuring that customers received their orders promptly and correctly.

By enhancing fulfilment speed and accuracy, the solution helped strengthen JL’s next-day and same-day delivery services, a critical factor in maintaining high customer expectations in today’s competitive retail market.

Beyond these immediate gains, the scalable and flexible solution equips JL to adapt to future growth and evolving market demands. Additionally, by revitalizing existing infrastructure and enhancing operational efficiency, the project contributes to long-term sustainability, aligning with modern business priorities.