Automation and Optimization
Smarter, faster, automated fulfillment.
THG Fulfil’s advanced automation and in-house technology deliver industry-leading performance, efficiency, and scalability across every stage of the fulfillment journey with our mature in-house development team driving continuous innovation.
Acutely investing in all types of technology and automation, powered by a mature in-house development team:
Over $200m invested in state-of-the-art, purpose-built, direct-to-consumer distribution facilities, defining the gold standard for ecommerce fulfillment globally.
Over $70m invested in automation across our global estate, enabling unrivaled speed of service, 24/7 operations, maximized stock & pick accuracy, class-leading NDD cut-off times, as well as protecting our clients from labor inflation.
Millions of development hours invested in building proprietary technology to control and optimize every part of the fulfillment and delivery journey (WMS, CSM, OMS, WCS, CX).
AutoStore is a cutting-edge automated storage and retrieval system (AS/RS) designed to maximize space, boost efficiency, and streamline fulfillment.
Our autonomous robots navigate a high-density cube storage grid, retrieving goods with precision and speed - delivering a seamless, scalable, and sustainable solution:
- Up to 75% less space usage compared to traditional shelving.
- 24/7 operations with significantly reduced picking times.
- Seamless scalability by adding more robots or grid modules.
- Energy efficiency, as the robots consume minimal power, making AutoStore a sustainable fulfillment solution.
A continuous approach to system
development and optimization
At THG Fulfil, we take a unique approach to system optimization, pushing beyond standard automation capabilities to maximize efficiency and performance. While many automation providers operate within fixed system specifications, our goal is to exceed these limitations through advanced optimization techniques.
Instead of simply investing in new technology, we ensure that every system and process is fully optimized to deliver peak efficiency before further investment is considered.
Our optimization strategy begins even before products arrive at the warehouse. We analyze key characteristics of inbound inventory, delivery profiles, and opportunities to reduce costs at every stage of the supply chain. By mapping both optimal and suboptimal paths in the inbound process, we create a comprehensive strategy to enhance efficiency from the outset.
Our data teams employ advanced algorithms, incorporating graph theory, mathematical modeling, and proprietary THG Fulfil intelligence to determine the most efficient storage locations and logic. This not only reduces costs and improves storage capacity but also strengthens our outbound strategy, ensuring seamless operations throughout the year.
Utilizing continuously evolving proprietary software, we further refine storage positioning, product distribution, and pick strategies based on order types.
We develop tailored strategies for different workflows, ensuring that order patterns, product commonality, batch-ability, and order age are intelligently processed. This allows us to maximize operational efficiency and dynamically scale volume requirements as needed.
Every system change at THG Fulfil undergoes rigorous real-world and software-based modeling. Our data scientists collaborate closely with operational excellence teams to simulate and test modifications in real time, ensuring measurable benefits before implementation.
From optimizing putaway logic to refining pick strategies, we leave no aspect of the process unexamined. At THG Fulfil, every decision is driven by data, technology, and a relentless focus on efficiency, enabling us to deliver industry-leading performance at every stage of our operations.
Industry leading performance at scale.
Powered by our proprietary Warehouse Control System (WCS) and Warehouse Management System (WMS), we’ve continuously optimized AutoStore since 2021, transforming our site into the world’s highest direct-to-consumer (D2C) output facility and achieving industry-leading efficiency. This includes:
11,790 outbound bin presentations per hour
Setting a new global benchmark.
Intelligent batching algorithms
Enhancing throughput while minimizing cycle times.
Bin wait times reduced from 8.71s to 4.52s
Doubling system responsiveness.
User wait times cut from 21s to 13s
Streamlining fulfillment operations.
Optimized packing stations
Boosting productivity with advanced rebin-to-light systems.
Smart space utilization
Live data-driven strategies maximize bin compositions.
AutoStore isn’t just a storage solution.
Coupled with THG Fulfil’s proprietary technology and optimization know-how,
it’s a game-changer for scalability, speed, and sustainability.
Alternatively, achieve significant productivity improvements and scalable picking operations through Geek+ shelf-to-person robotics.
- Batch Pick to 388 Shipments
- Batch Pick to 32 Shipments
- Batch Pick to 12 Shipments
Utilize Geek+ for pick-to-order and batch picking. We implement various batch picking methods, enabling scalable picking operations based on volume requirements and cycle time requirements. Each process is tailored to optimize efficiency and meet operational demands.
We continuously monitor system performance to refine Geek+ operations and system developments:
Enhanced putaway logic to optimize space utilization and improve picking efficiency.
Advanced SKU placement strategy, directing items to specific shelf heights based on sales velocity.
Stackable product solutions to maximize space efficiency using standard volumetric capture technology.
Aged inventory prioritization, improving pick priorities according to cutoff times.
Optimized storage logic, positioning fast-moving items closer to outbound ports for quicker access.
Robot routing improvements to enhance presentation efficiency.
Robot queue changes to reduce operator wait times.
Consolidation processes to optimize space management.
Pack-to-light system development, with the next step being pick-to-light projection.
More from THG Fulfil
Why THG Fulfil
We create seamless customer experiences that drive brand growth, loyalty and impact. Turning ecommerce fulfillment into your competitive edge.
Reports
Access valuable insights, tools, and guides to help you optimize fulfillment and scale smarter in today’s fast-moving ecommerce world.
Case studies
Discover how brands like Holland & Barrett, Cult Beauty, Biossance, and Dermstore scale faster with THG Fulfil.
Why Choose THG Fulfil?
We are the operational backbone behind some of the world’s fastest-growing brands and largest retailers. With a world-class global infrastructure, we’ve spent the last 20 years transforming our own brands into industry leaders, quickly moving beyond the limitations of outsourced 3PLs in the early years to develop our proprietary operational ecosystem. This cutting-edge infrastructure and technology give us complete control over the customer delivery experience, ensuring seamless, end-to-end execution at scale.
