iForce: automate 3PL intralogistics processes

iForce are part of the Culina group and have almost 30 years’ experience as a 3PL, particularly within the eCommerce fulfilment and returns sector providing services for some of the biggest names in retail. In recent years iForce have invested significantly in technology, particularly within warehouse robotics and automation.

They have recently implemented the Skypod® system from Exotec through its UK partner L-A-C Logistics Automation, at their iForce House site in Corby, Northants.

In recent times, iForce has faced many of the challenges typical of the 3PL sector. Increasingly variable and erratic client volumes and challenges in finding suitable labour together with increasing costs have all combined to add risk to iForce’s ability to deliver for their clients. To counter this, iForce developed a warehouse automation strategy, resulting in significant investment in a combination of robotic goods-to-person picking, robot assisted picking and automated packing systems.

• It was critical that all elements, plus all of the other manual warehouse processes, should work perfectly in parallel and in combination with each other, and ultimately be managed by iForce’s own WMS.
• Each element should be space efficient, be able to be implemented independently or as part of a larger solution, at any of iForce’s sites, and must be able to be scaled independently.

After careful evaluation of the available solutions, the Exotec Skypod system was selected as a key component of the strategy. // // La solution déployée devait s’adapter à l’écosystème intralogistique existant dans les entrepôts.
C’est pourquoi iForce a choisi Exotec et son système d’automatisation de process intralogistiques Skypod ; une solution flexible, autonome et efficace qui s’accorde aux spécificités des flux intralogistiques du secteur 3PL.

The Exotec Skypod system was installed by our partner, L-A-C, at the flagship iForce Corby site during 2022, going live in early 2023.

The iForce Corby site is a 880k sqft multi-user facility providing services to clients such as The Works, Naked Wine, Fortnum & Mason and Mayborn.

The Skypod system installed at iForce consists of Autonomous Mobile Robots (AMRs) able to move in three dimensions, coupled with a high-density storage system, that has enabled iForce to optimise space within its warehouse and improve intralogistics flow management times. //

The efficiency of the Skypod AMRs ensures that the throughput can be maintained 24/7, and peaks in intralogistics flows can be managed calmly and quickly by adding additional robots if required. In summary, what does the Skypod solution bring to iForce?

Significantly enhanced capacity to deliver increasing customer order volumes

Flexibility to adapt to changing customer profiles. The Skypod system of racks, bins and robots can be easily independently scaled to increase storage or throughput capacity. Indeed, further scaling of the Corby solution is already being planned for 2025

The Skypod system works in conjunction with other robotics, automation and manual processes across the site, ensuring a seamless workflow through the warehouse

Compact footprint 98% guaranteed availability, backed up by 24-hour remote monitoring of the robots. Expert technicians are also deployed on site to carry out preventive and corrective maintenance.

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In addition to meeting the immediate needs of leading logistics service providers such as iForce, the Skypod warehouse automation system makes it possible to anticipate future challenges specific to the entire 3PL sector.

• Improve scalability for future growth.
• Increase throughput and processing capacity.
• Optimise traffic, sequencing and picking.
• Accurately manage high order volumes to absorb peaks in activity and meet demand.
• Integrate additional robots if requirements change.
• Support reactive order picking, with the option of adapting the system by adding robots or increasing the storage size within tight deadlines: system scalability and modularity. // Guarantee a maintenance and support service for AMRs.