Xtep
ACR warehouse
Xtep
As a public-focused enterprise specializing in sports goods, Xtep has always been committed to providing consumers with personalized and cost-effective sports products. In recent years, the company has achieved rapid business growth through a multi-brand strategy and international expansion. However, challenges in warehouse management have become increasingly apparent, especially in meeting demands such as handling scattered carton batches for inbound storage and consolidating SKUs of the same style and color for shelf placement. To address these issues, Xtep urgently needed an efficient buffering warehouse to store and consolidate scattered cartons before palletizing and shelving. To meet this need, Sidonn and Hai Robotics jointly developed an intelligent tote-based warehouse system, offering an innovative solution.
The revamped buffering warehouse, covering an area of approximately 2,200 square meters, has achieved efficient space utilization through an upgraded design, increasing storage density threefold compared to the traditional ground storage method. The warehouse uses HaiPick A42T robots to handle high-level goods retrieval and placement. The upper levels of the racks are designed for single carton storage, while the bottom levels serve as buffering workstations for tasks like inventory checks, palletizing, and outbound processing. This layout enables “storage above, picking below,” eliminating the need for additional workstations.
The lower three levels of the central racking area are reserved as a manual picking zone, offering a dedicated picking area for single items or low-quantity SKUs. Robots and manual operations are staggered to further improve overall efficiency.
In practice, handling scattered cartons during inbound storage is common. In such cases, warehouse staff consolidate products of the same style into full boxes or pallets before storing them in the tote storage area or pallet zones. With the tote storage section in place, replenishment has shifted from pallet-level to box-level operations, aligning better with workers’ workflows.
Once quality-inspected, SKUs are grouped into assigned boxes and further consolidated into pallets, stored in the pallet zone adjacent to the tote warehouse. This method significantly increases pallet utilization rates, reduces high-level forklift retrieval tasks, and shortens the time from inbound to outbound processing, optimizing operational efficiency.
In terms of management, the warehouse leverages the HaiQ smart warehouse management platform and its ESS (Equipment Scheduling System). This system allocates resources in real-time based on upstream task commands, ensuring robots operate efficiently and orderly. As a result, the warehouse achieves a throughput of 210 boxes per hour, fully accommodating diverse operational needs and propelling Xtep’s warehouse management into a new era of smart logistics.
By offering an innovative multi-format intelligent mixed storage solution, Sidonn and Hai Robotics have significantly simplified the end-to-end processes of receiving, box consolidation, and shipping for Xtep’s footwear and apparel goods. This improvement not only enhances sorting accuracy but also makes inventory handling far easier for staff. As a leading brand in the footwear and apparel industry, Xtep's deployment of a high-efficiency ACR intelligent warehouse sets a benchmark for the digital transformation of other sports brands.
