Exotec, a designer and integrator of robotic options for warehouse logistics, has introduced the deployment of a multi-site programme referred to as Skyfleet for Decathlon.
This system spans seven logistics platforms throughout 5 European nations: France, the UK, Portugal, Italy, and Germany. Past enabling Decathlon to standardise and handle logistics flows at a European scale, the programme has additionally improved working situations inside warehouse groups.
This initiative marks a brand new milestone in positioning Exotec as an end-to-end integrator, orchestrating all warehouse flows and gear – from inbound to outbound – inside a unified structure.
The programme created for Decathlon is a devoted implementation of this strategy, designed to speed up multi-site deployments internationally by means of course of standardisation.
Standardising retailer replenishment throughout Europe
After deploying its first Skypod robotic system on the Tilburg website in 2021, Decathlon selected to increase the partnership with an much more formidable challenge, standardising retailer replenishment throughout the European continent.
Exotec developed a devoted programme constructed on a harmonised, replicable, and scalable structure; one that allows the rollout of a standardised mannequin whereas nonetheless adapting to every website’s particular necessities.
Every Skyfleet system follows a constant configuration:
- A fleet of 150 to 200 Skypod robots
- 100,000 to 125,000 storage places
- 3,000 to 4,000 order traces per hour
- 150,000 to 200,000 gadgets processed per day
- 7 to 13 selecting stations (single stations and stations with order movers)
- Parcel buffering earlier than expedition inside the identical storage system
- Full automation of inbound and outbound flows
Standardised end-to-end integration
At each Decathlon website, Exotec systematically integrates extra automated gear to optimise intralogistics processes: computerized depalletisers, automated carton-opening machines, RFID tunnels, computerized palletisers, and extra.
For these specialised machines, whose choice in the course of the design part could be pricey and time‑consuming, mutualising decisions throughout websites generated vital economies of scale.
Past system design, the shared construction and learnings gathered all through the programme assist speed up deployment phases, significantly the efficiency ramp-up interval.
As with all Exotec tasks, circulation orchestration and gear coordination are dealt with by Deepsky, Exotec’s proprietary warehouse execution system (WES). This software program layer unifies interfaces and ensures seamless endtoend operational continuity.
Standardising websites additionally enabled Exotec to develop a single software program codebase, shared throughout all seven warehouses, and simplifying deployments additional.
Collaborative know-how benefiting groups
Standardisation additionally made it simpler to help and practice groups adopting new applied sciences. By eliminating most heavy handbook dealing with, workers had been in a position to upskill and tackle new actions whereas persevering with to help the corporate’s development.
The Skyfleet programme considerably improved working situations for Decathlon warehouse groups. For instance, on the Northampton (UK) website, a picker would stroll 10km per day, however inside the new programme, they now stroll simply 1km per day. The variety of office incidents associated to order preparation has additionally sharply decreased, from one per 5,000 to 1 per 10,000.
Important efficiency enhancements
The brand new implementation enabled most Skyfleet websites to extend the variety of Decathlon shops they provide. That is the case, for instance, in Ferrières (France), now supplying 73 shops vs 37 beforehand, and in Setúbal (Portugal), which now provides 73 shops vs 41 beforehand.
The variety of orders ready each day additionally elevated considerably. The Setúbal website now prepares 114,000 orders per day, in contrast with 57,000 earlier than Skyfleet’s implementation.
Standardisation has additionally streamlined operations and long-term upkeep. Whereas every website stays domestically managed, Decathlon has launched harmonised instruments and dashboards, enabling groups to check efficiency, share finest practices, and optimise operations throughout warehouses.
Every system is designed to adapt to evolving buyer wants and help quantity surges. For instance, robots have been briefly transferred between warehouses to help peak exercise in particular nations. Moreover, the Ferrières website has already ordered 13 extra robots.
Jérôme Saillour, head of logistics automation at Decathlon, says: “We had been searching for a accomplice to help our logistics community rationalisation challenge. We selected Exotec as a result of they had been in a position to deploy a number of websites in a short while and combine scalable options that evolve with our wants.
“In 5 years, we’ve profoundly reworked the office expertise inside our warehouses and written the following chapter of logistics at Decathlon.”
A standardised structure to drive efficiency at European scale
By way of its multi-site deployment programme, Exotec has bolstered its place as an endtoend integrator able to supporting worldwide warehouse automation tasks.
Romain Moulin, co-founder and CEO of Exotec, says: “After we launched our first Skypod robotic system practically ten years in the past, we introduced extra flexibility and resilience to storage and order preparation.
“As intralogistics has develop into a strategic precedence for our purchasers, we now create worth all through all the warehouse. With the Skyfleet program, we’ve demonstrated our capability to orchestrate multi-site deployments.”
