Spare parts logistics automation: the Renault Group revolutionises order preparation, from 2 hours to 15 minutes thanks to the Skypod® system

To speed up spare parts logistics and spare parts warehouse automation, the Renault Group turned to Exotec’s Skypod® system, an elegant AS/RS system that has enabled order processing times to be reduced from 120 minutes to just 15 minutes.

The Renault Group, a world leader in the automotive sector, stands out for its ongoing commitment to innovation and process optimisation, particularly in logistics. This commitment is exemplified by the simplified management of the spare parts supply chain, overseen by the company’s Spare Parts and Accessories Logistics Department (DLPA).

The Challenge

The Renault Group faced a number of significant challenges in managing spare parts logistics in Europe:

• Fragmented distribution system: warehouses were organised by part type rather than by region, creating inefficiencies.
• No dedicated warehouse for France: limited capacity to meet domestic demand, which accounts for 37% of DLPA operations.
• Outdated systems: obsolete equipment and technologies hinder customer service quality and innovation.

To overcome these challenges, the Renault Group reorganised its spare parts warehouse network in France, focusing on centralising operations and customising sites to specific market needs. At the heart of this effort was the Villeroy facility, which was completely modernised with the Skypod® system as its core technology and designated as the main distribution centre for the French market.

The Skypod® system solution

Using the Skypod® system as its core technology, Exotec has integrated a wide range of additional solutions for end-to-end automation, including:

• A range of specialised machines, including: carton forming and sealing systems, printers for packing lists and RFID labels, a wrapping machine and 30 ergonomic grippers, all designed to increase speed and precision.

• Retail label printers at picking stations improve inventory traceability and stock management.

• A waste collection system integrated into the injection stations ensures efficient waste management and a cleaner working environment.

Key results

Revolutionary performance

• Over 5,000 lines selected per hour with only 14 Skypod® system operators.
• Order processing time has decreased dramatically, from 120 minutes to just 15 minutes, enabling faster fulfilment.
• Capacity to store and retrieve over 1.6 million items in just 3,450 m², which is slightly more than half the size of a football pitch.

Operational stability and cost savings

• Centralisation of over 80% of French operations in a single facility thanks to the Skypod® system’s ability to manage omnichannel order fulfilment and seamlessly adapt to dynamic order demands.

Improving customer service

• Orders placed before 5:30 p.m. are delivered by 8:00 a.m. the following day, which is a significant advantage in terms of responsiveness and convenience.
• It has achieved a customer satisfaction rate of over 99.7%, reinforcing its reliability and speed of order fulfilment.

“Meeting deadlines and achieving our growth curve was a major challenge. We are satisfied with the results achieved so far and are preparing to finalise the organisational transformation around this new structure.” – Louis Szukics, Warehouse Engineering Manager – Transformation Division, Renault Group

Ready to Transform Your Warehouse?

The timely availability of the correct spare part is now a secure and controllable process. With Errevi Automation’s tailor-made warehouse logistics solutions, it is possible to automate the warehouse, optimise flows and picking times, significantly increasing operational efficiency.

Discover how to transform your warehouse into a smart, high-performance facility.