INTERSPORT Masters the Largest Logistics Project in Company History

Expanded capacity, modernization of central logistics, improved efficiency and speed of delivery to the B2B branches throughout Germany: The largest project in the history of the INTERSPORT Group to date has been successfully completed — during ongoing operations, on budget and on schedule. The FORTNA consulting team developed a complex intralogistics concept, implemented over five project stages during ongoing operations, and provided expert support to the INTERSPORT Group throughout the entire project, acting as their sounding board and sparring partner.

The solution

As part of the step-by-step plan for the INTERSPORT Group, the services provided by FORTNA include supporting the merger of the warehouse, distribution, and fulfillment operations of INTERSPORT Germany and INTERSPORT Austria in the form of an inventory and evaluation of the logistics systems and the supply chain. On this basis, the medium- and long-term logistics strategies were developed together with INTERSPORT Germany.

The following measures were implemented: The optimization of the order picking systems and the selection of a fulfillment service provider to outsource the handling of bulky goods. FORTNA also developed a complex solution design for the expansion of the central warehouse at INTERSPORT Germany’s headquarters in Heilbronn and provided support in the reorganization of the warehouse management system IT (WMS IT).

The expansion measures, which were implemented over five project stages during ongoing operations, in detail:

The construction of a new high-bay warehouse, 6,000 m² floor space, 36 m high. To optimize processes, the new building was connected to the existing building, and additional storage areas were set up for order picking. Replenishment and order picking were automated through the introduction of conveyor technology and shuttle vehicles, and an automated carton warehouse and a shuttle warehouse were also implemented. With a capacity of 120,000 cartons in the automated small parts warehouse and 40,000 storage locations in the shuttle warehouse, INTERSPORT Germany now has a total of 160,000 additional storage locations. The processes in the new incoming goods area have also been automated and optimized: the incoming cartons are recorded fully automatically by an OCR camera system and are transported to the upper floor via conveyor technology.

Six miniload stacker cranes and 37 shuttle vehicles per shuttle aisle ensure that up to 1,800 cartons per hour are stored and retrieved correctly. The final expansion stage includes automatic carton erectors and new shuttle picking stations. Pick-by-light technology is used to pick the individual items directly into the shipping cartons, which are then transported to the packing area on the ground floor. Further upgrade here: New high-speed packing stations and automatic strapping machines.

Simultaneously, INTERSPORT Germany faced the challenge of quickly establishing its own structures and identifying additional storage and dispatch capacities, following Nike’s decision to discontinue direct delivery of sporting goods to INTERSPORT shops across Germany. The service provider already used for bulky goods handling was able to provide the required logistics space in a new hall. Together with FORTNA, the layout, processes, and IT structures for handling were developed, and various storage areas were set up for order picking, with pre-order and post-order being considered separately.

FORTNA Can Help

FORTNA helps organizations to remain sustainable and competitive in the long term and to meet changing distribution challenges, increasingly complex supply chains and growing demands for speed of delivery and customer service.

Images: INTERSPORT Germany eG

Published/Updated 11/20/24