250% Increase in Efficiency for Order Picking & Fulfillment Operations With Advanced G2P ASRS

Advanced Goods-To-Person Automated Storage & Retrieval Systems

Streamlining in-store replenishment and delivering a seamless omnichannel customer experience.

Boot Barn, the world’s largest retailer of Western wear, has seen explosive growth across the U.S. in recent years. But when you’re scaling a business of this size, you’ve got to ensure that your distribution and logistics can keep up with the demand. This is where everything comes together, and it all starts by having the right partners on board. Boot Barn knew that to maintain its growth, it needed a smart, efficient system in place to handle the increasing volume of products flowing through its Kansas City distribution center. Enter IndPro, along with partners SSI Schaefer and Hai Robotics, to help revolutionize the entire operation. And it’s clear their contribution has been a game-changer.

IndPro’s role in this project was pivotal, especially when you consider the complexity of modern E-commerce operations. They didn’t just walk in with a one-size-fits-all solution; they tailored a system that truly meets Boot Barn’s unique needs. At the heart of it is the HaiPick Automated Storage and Retrieval System (ASRS), a state-of-the-art piece of technology that uses robots to handle storage and retrieval tasks with impressive speed and accuracy. IndPro’s expertise came into play by seamlessly integrating this advanced tech into the distribution center’s workflow.

The outcome? A doubling of storage density. That means Boot Barn can now store twice as many products in the same space – which, if you think about it, is a huge deal for any company managing high-volume inventory. But it wasn’t just about squeezing more items into the warehouse; it was also about handling them faster and more efficiently. Thanks to IndPro, throughput shot up by a massive 250%, allowing Boot Barn to process and move products at a pace that would have been impossible before.

Doubling Storage, Slashing Costs, and Powering 500K Units a Week

With their integration partner’s help, Boot Barn slashed labor costs by 50%, an incredible feat in an industry where labor can eat up a huge chunk of your operational budget. Now, the Kansas City facility can handle more than half a million units each week. Think about that – within one week – over 500,000 products, sorted, stored, and shipped out to stores and customers across the nation.

This level of operational efficiency has positioned Boot Barn to keep expanding without worrying that its backend logistics will fall behind. All in all, IndPro, SSI SCHAEFER and Hai Robotic’s contribution isn’t just a boost to productivity; it’s been a vital part of ensuring that Boot Barn can scale its operations smoothly, meeting customer demand while keeping costs under control. It’s a textbook example of how the right technology and the right partners can transform a business.

Results: Revolutionized Distribution Center for Boot Barn KC

• 34-foot high, lights-out ASRS shuttle system
• 250% increase in efficiency
• 100% picking accuracy
• 50% increase in storage density
• 50% reduced labor cost
• Moving 460 totes per hour
• Handling over 500,000 units per week
• Streamlined operations for future growth