GEODIS’ Automation Journey: High-Throughput Omnichannel Order Fulfillment

Johnathan McRary & Dan Cahalan | 19 February 2025

When Maurice’s, a women’s retail fashion brand, set out to reimagine its distribution strategy, it turned to GEODIS, a global leader in third-party logistics, to bring its vision to life. Tasked with designing and managing a 404,000-square-foot omnichannel distribution center, GEODIS needed a fulfillment system that could handle retail replenishment, direct-to-consumer shipping, and buy-online-pick-up-in-store (BOPIS) orders—all while keeping up with rising customer expectations and order volumes.

To tackle these challenges, GEODIS sought a solution to deliver high-throughput capabilities and adapt to future growth. Their search led them to AutoStore, a proven order fulfillment technology, and Bastian Solutions, a trusted integrator with extensive experience in implementing automated systems.

Through this collaboration, GEODIS and Bastian Solutions created a cutting-edge distribution center that balances speed, flexibility, and efficiency. With AutoStore at its core, the facility is equipped to meet the demands of today’s fast-paced retail logistics environment while remaining ready to scale for what’s ahead.

The Role of High-Throughput in Logistics

High throughput—the ability to process large volumes of orders quickly and accurately—is critical for businesses balancing retail and e-commerce operations. In omnichannel fulfillment, where speed and precision directly impact customer satisfaction, achieving this level of efficiency is a competitive necessity. For instance, a delayed online order can tarnish a customer's shopping experience, whereas rapid fulfillment ensures loyalty and repeat business.

The AutoStore system at the GEODIS-managed facility for Maurice's exemplifies high throughput in action. Handling up to 450,000 units daily, the system operates with 320 robots navigating a 92,000-bin grid. Its modular design ensures scalability—robots, bins, or ports can be added to support peak demands or long-term growth. This adaptability allows GEODIS to stay ahead in a fast-paced market, maintaining smooth operations even during seasonal spikes.

Collaborative Innovation: Geodis and Bastian Solutions

The partnership between GEODIS and Bastian Solutions focused on building a solution that could integrate automation into their omnichannel strategy for Maurice's. Bastian Solutions brought their AutoStore expertise to the table, working closely with GEODIS to craft a system tailored to the project's specific needs. Together, they designed a fulfillment system that addressed current challenges and anticipated future ones, such as handling seasonal demand spikes and shifting order profiles.

Key features of the solution include:

• 320 robots managing a dense storage grid of 92,000 bins.
• Bastian Solutions SmartPick™ stations for automated picking and order processing.
• Integrated conveyors and automated packing equipment to streamline the flow of goods.

This cohesive solution balances speed, flexibility, and accuracy, equipping GEODIS to handle fluctuating demands while maintaining exceptional service levels for Maurice's.

The Role of AutoStore Technology

The AutoStore system's advanced features power GEODIS's high-throughput success in managing Maurice's fulfillment operations. Bastian Solutions' SmartPick goods-to-robot system automates picking processes, while Bastian’s Exacta intralogistics software coordinates system operations, to support task management and channel transitions. The Exacta software also provides real-time insights into operational efficiency, allowing GEODIS to adapt quickly to shifting priorities and ensure smooth order fulfillment.

AutoStore delivers ergonomic benefits for employees by reducing physical strain by automating repetitive tasks. Workstations are designed for comfort, improving both safety and efficiency. This thoughtful design fosters a safer and more satisfying work environment, contributing to long-term employee satisfaction and productivity.

Delivering Omnichannel Distribution Results

The implementation of the AutoStore system has yielded positive results for GEODIS in managing Maurice's distribution:

• Increased Throughput: Processing up to 450,000 units daily during peak periods.
• Cost Reduction: Operating costs reduced by 30%, primarily by decreasing labor requirements and optimizing packaging to save materials and maximize truck space.
• Enhanced Productivity: Employee productivity increased by over 60%, with new team members reaching target productivity in just 1.5 weeks, down from the usual 4 to 6 weeks.

These metrics don't just benefit GEODIS's operational efficiency—they enhance the end customer experience for Maurice's by ensuring faster deliveries and fewer errors. The system's reliability and scalability allow GEODIS to meet customer expectations while adapting swiftly to demand fluctuations.

Future-Ready Fulfillment

AutoStore is built for growth, offering modular scalability that allows businesses to expand without overhauling infrastructure. Robots, bins, and ports can be added as needed, ensuring the system evolves alongside operational demands. For example, during a busy holiday season, adding a few extra robots or bins allows the system to scale up without disrupting ongoing operations.

For GEODIS, this forward-thinking solution positions them as a leader in efficient logistics. By partnering with Bastian Solutions and leveraging AutoStore technology, GEODIS has future-proofed Maurice's operations, ensuring they can easily navigate market changes while delivering superior customer service.

Transforming Logistics: Your Next Step

The partnership between GEODIS and Bastian Solutions showcases the transformative potential of AutoStore technology. By combining high throughput, scalability, and adaptability, the system sets a new standard for omnichannel logistics.

Read the full case study.

With proven expertise, Bastian Solutions offers a pathway to efficiency and innovation for businesses ready to elevate their fulfillment operations. If you're ready to explore how AutoStore can revolutionize your operations, connect with a Bastian Solutions engineer today to discuss your needs and build a solution tailored to your business.

Author: Dan Cahalan, Johnathan McRary