Case Study: Woolworths achieves higher throughput and capacity with Dematic upgrade

Dematic upgrade refreshes Woolworths Mulgrave

Woolworths, a major Australian retailer, faced significant challenges at its Mulgrave National Distribution Centre (NDC). An ageing and complicated Dematic automated order picking and sortation system, originally designed for a much smaller operation, was struggling to meet the demands of servicing over 800 stores nationwide. The outdated technology restricted throughput capacity, added operational costs, and required a major upgrade that had to be managed within a live environment without disrupting daily business.

Dematic implemented a comprehensive solution that included significant mechanical, electrical, and software upgrades. Key components involved installing new accumulation conveyors, reconfigureing the crossbelt sorter, introducing voice-directed picking, and integrating a new warehouse management system with Dematic’s proprietary PickDIRECTOR software. As a result, the Mulgrave NDC now fulfills twice as many orders, distributing over one million cases weekly. The crossbelt sorter's capacity dramatically increased from 6,400 to approximately 11,500 cases per hour, providing the capacity to service over 1,000 stores by 2020.

WoolWorths

Aaron Ford

Project Manager