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Case study Leroy Merlin

The Company

Leroy Merlin is a chain of building materials, finishing, decoration, gardening and DIY stores, founded in France in 1923 by Adolphe Leroy and Rose Merlin.

Leroy Merlin has 310 stores worldwide, with 36 thousand employees and revenues of 6.6 billion euros (approximately R$ 18.1 billion). Since its arrival in Brazil in 1998, opening a store in Interlagos, Leroy Merlin has been expanding throughout the country, with more than 80 thousand items in 15 sectors: Building Materials, Wood, Electrical, Tools, Rugs, Ceramics, Toiletries, Plumbing, Gardening, Hardware, Painting, Decoration, Lighting, Organization, and Kitchen. The stores also offer services such as wood and glass cutting, framing, and the custom-made curtains, among others.

CUSTOMER NEEDS

To keep up with the growing demand of its customers, Leroy Merlin considered it was necessary to evolve its traditional operational model. In order to ensure ergonomics, productivity, reduce turnover and guarantee scalability of the business, the company needed a logistics solution that would optimize area, time and resources of its distribution center in Cajamar, a city in São Paulo state.

Leroy Merlin, within its growth strategy, sought Cassioli for the construction of an automated warehouse, an innovative automation solution that makes it possible to move even the heaviest products with greater agility. The project aims to reduce pallet handling time, perform separation by batch picking, and ensure efficient and high-density storage in accordance with the material turnover curve. In addition, ergonomic picking stations will be designed with box separation aided by handling equipment and structures that will ensure a safe process, maintaining the integrity of the material and the operator. The project started with an analysis of the data from statistic flow to calculate the system and deliver the products to their destinations as requested by the operation system.

The Cassioli solution

Cassioli presented a complete solution to ensure an increase of efficiency of the entire logistics system, consisting of six stacker cranes with 2 tons capacity each and double-depth pallet rack structures with a capacity for more than 19,000 pallets.

The transportation of products inside the warehouse will be made by roller and chain conveyors, and the picking bays will be equipped with pantographic tables, stability devices, and gravity zeroing manipulators. It will also have automatic stacking and unstacking handlers for empty pallets, automatic slave pallet feeding systems at the entrance of the equipment, and automatic feeding pallets delivery at the order preparation stations.

Advantages

AREA OPTIMIZATION
AND LOGISTICS EFFICIENCY

SAFETY AND OPERATIONAL
COSTS REDUCTION

REDUCTION OF THE DAMAGES
WITH STORED MATERIALS

CONTINUOUS MONITORING
OF
PERFORMANCE AND
TRACEABILITY

AUTOMATED
HANDLING
OF
PRODUCTS

MAXIMUM
ORGANISATION OF WORK SITE

STORAGE CONTROL WITH
CASSIOLI WMS AND TOTAL
INTEGRATION WITH
CUSTOMER’S ERP

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