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L.L.BEAN: MODERNIZING OMNICHANNEL FULFILMENT WITH BEUMER GROUP

Increasing order capacity and maximizing the capabilities of an existing distribution center
SEE THE L.L.BEAN SOLUTION IN ACTION

SUPPORTING GROWTH THROUGH SORTER MODERNIZATION

L.L.Bean’s million-square-foot order fulfilment facility processes an average of 45,000 customer orders a day. As demand continued to grow, L.L.Bean turned to BEUMER Group to modernize and expand the packing sorter at its Freeport, Maine distribution center.

The goal was to increase order capacity, maximize system capabilities and create the infrastructure needed to support future omnichannel growth.

  • 45000

    average customer orders processed per day

  • 37028

    trays per hour of total mechanical capacity

  • 31000 +

    units per hour sorting capacity

MAXIMIZING THE EXISTING FACILITY

More capacity and flexibility without expanding into additional real estate

The existing packing sorter operated with a pre-sorter and two-pass sorting process that limited throughput and productivity. Rather than expanding into additional facilities, L.L.Bean wanted to maximize the capabilities of its existing distribution center.

BEUMER Group reconfigured the control system and electromechanical layout to provide four virtual sorters within one system. A new induction platform also freed up space for 140 new packing chutes, while existing packing chutes were equipped with new controls.

IMPROVING CAPACITY AND WORKFLOW

A modernized sorting process designed for greater operational efficiency

The upgraded packing sorter provides greater flexibility for wave-based order processing while also improving the working environment for operators. By reconfiguring the control system and electromechanical layout, BEUMER Group created four virtual sorters within one system. A new induction platform also freed up space for 140 new packing chutes, while existing packing chutes were equipped with new controls.

These upgrades allow a higher volume of orders to move through the system while making better use of L.L.Bean’s existing distribution center.

  • Products can be sorted into up to four pick totes corresponding to four sorter quadrants

  • Any pack wave can be directed to any quadrant or induction area

  • Enlarged chute areas and improved workstation visibility support more efficient packout

  • Faster chute availability allows a higher volume of orders to flow through the system

“Our transformation over the last few years has really extended the life of this facility. It’s allowed us to, essentially, double the capacity of this facility and do it cost-effectively.“

Wayne Steele, Director of Fulfilment & Logistics
L.L.Bean

SOLUTION HIGHLIGHTS
  • 4 virtual sorters configured within one system
  • Space created for 140 new packing chutes
  • 128 new Double-Level chutes installed and commissioned
  • 228 existing Double/Double chutes modified and recommissioned
  • Improved packing chute visibility and operator workflow
  • Ongoing maintenance, IT and operational training, and customer service support

L.L.Bean Case Study

Download (PDF, 3 MB) L.L.Bean Case Study
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Lars Beier Madsen - Sales Director, Logistic Systems

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