CASE Lenskart

Objective

Lenskart’s state-of-the-art manufacturing facility produces and distributes to not only the length and breadth of India, but to international markets as well, across different channels. The facility handles a wide array of SKUs, with the inventory consisting of 70% prescription glasses & eye frames, 20% contact lenses & lens solution, and the rest 10% divided between sunglasses and reading glasses. Out of total more than 1,10,000 SKUs, 60% of the business volumes derives from Class A inventory, 30% and 10% of volume derives from class B and C, respectively. The solution had to be designed in such a way that it could cater to the changing inventory levels across different categories, and also reduce the cost and time of fulfilment. The solution also had to ensure that the operations could support surged market demands and cater to the requirements of both physical stores and online customers. In order to ensure customer delight, the order consolidation time had to be brought down to few hours, instead of the existing 2-3 days. With the sensitive nature of eyewear, Lenskart also had to make sure the accuracy of their operations was 100%.

Solution Implemented

To fulfil Lenskart’s objectives and goals, Addverb helped in conceptualisation and designed a facility that would integrate all steps of the value chain namely manufacturing, warehousing and distribution. Addverb also finalised their material flow analysis and operational layout. Since the DC catered to both physical retail stores and online customers, it was important to use the right mix of fixed and flexible automation to ensure the fulfilment would be as per the requirement of the end-customer. To store the vast inventory and ensure fast picking, Quadron, Addverb’s carton-shuttle based Automated Storage and Retrieval System was implemented, which ensured utilisation of optimum space. Ergonomically designed Goods-to-Person (GTP) picking stations ensure efficiency and accuracy in order picking process. The Quadron system is ideal for order sequencing and buffering based on business requirements. Concinity, Addverb’s Warehouse Execution System, orchestrates the automation systems and coordinates the material flow to ensure the picking strategies and order sequencing are implemented to ensure on-time, infull deliveries. Post the picking and packing of orders, Concinity guides the order through a network of smart conveyors to the sorting area, where the order is further processed basis its destination distribution channel. SortIE, vertical sortation robot, was employed for physical store-based orders. For direct-to-consumer orders, a fleet of table-top robotic sorters (Zippy) was deployed to categorise orders into chutes as per logistics partners. Autonomous Mobile Robots (AMRs), Dynamos, are deployed to ensure the chutes are processed to the outbound area. AMRs work on Natural Navigation, enabling swift outbound to ensure orders are shipped on time.

Improvement in Key Results (KPIs)

The extensive solution, incorporating a diverse range of robots to automate warehouse tasks, boasts unparalleled and impressive Key Performance Indicators (KPIs). Order Consolidation time down to 2.5 hours/per order Achieved order fulfilment accuracy of 99.99% Efficiency of 2,00,000 orders dispatched/day Optimised storage density with 32,000 storage positions More than 40 GTP stations to ensure faster fulfilment. Capability to scale to store up to 3,50,00,000 eaches in future.