Meeting Growing Demand With High-throughput Automation

adidas Group wanted to ensure it reaches 83 percent of customers in its largest U.S. markets while reducing shipping times and improving service levels for customers. To meet this challenge, the company consolidated its U.S. distribution network into a greenfield site, where it invested in two distribution centres covering more than 186,000 square meters (2 million square feet).

To support adidas Group, Honeywell designed two high-volume throughput solutions:

• Waterfall induction for shirts, shorts, sweatshirts, pants and other clothing
• Domino induction for shoeboxes

Apparel is picked from individual storage and full cases and bulk-dumped into gaylords, which are then sent onto a collection conveyor. This process is more efficient and faster than manual methods. Honeywell also created a system of belt transportation conveyors to move products from the ground floor to induction stations overhead.

To eliminate manual handling of shoeboxes, Honeywell designed a V-belt driven roller conveyor. Stacks of four to eight shoeboxes can be deposited vertically onto the conveyor. Employees load multiple items in one motion, rather than one or two shoeboxes at a time. The conveyor catches the end of each box and topples or dominoes it onto the conveyor.