DSL Logistics, a rapidly expanding third-party logistics (3PL) provider in New Zealand, has significantly enhanced its operational capabilities by implementing Infios’ AutoSort Mobile robotics at its Auckland distribution centre, achieving a remarkable 30 per cent improvement in processing efficiency. This strategic move, completed just in time for the peak season, is projected to deliver a full return on investment within four years and has solidified DSL's standing as the leading 3PL for apparel and footwear brands in the country.

Faced with a confluence of challenges including escalating labour shortages, rising wage pressures, and the relentless surge in eCommerce demand, DSL Logistics, which has impressively doubled in size over the past five years, sought an innovative solution to modernise its sortation processes. The answer came in the form of Infios’ autonomous mobile robots (AMRs). This advanced system employs tabletop sortation robots that autonomously transport items to stationary staff at ergonomic sorting stations, thereby eliminating time-consuming manual travel and significantly streamlining throughput. 

Aaron Hobbs, Operations Director at DSL, highlighted the critical need for this technological leap: “Struggling with attendance, reliability and rising wage costs meant we needed to innovate beyond traditional manual processes”. He added, “The fact that we pulled the trigger 18 months ago has put us a couple of years ahead of the competition. We’ve built the confidence and integration, and now we’re ready to automate more”. 

The implementation, fast-tracked to go live in August 2024 ahead of DSL’s busiest period, showcases a modular design that allows the company to efficiently handle inventory for 40 different clients using a single, centralised robotic sortation system. Items are shuttled from five separate warehouse sites into this advanced system. Beyond core sortation, the robots have also bolstered DSL’s flexibility in managing returns and producing custom ratio packs – pre-configured product sets tailored to specific retailer size and style allocations . The intuitiveness of the system is another key benefit, with Hobbs noting, “The system is remarkably intuitive – we can train new staff in just five minutes, which proved invaluable during the seasonal ramp-up”.

A crucial aspect of this success story is the seamless integration of the Infios robotics solution with DSL Logistics' proprietary warehouse management system (WMS). This synergy has created a highly accurate process, maintaining near-perfect order fulfilment rates . Such integrations are vital in modern logistics, ensuring that new technologies enhance, rather than disrupt, existing workflows.

Andrew Leslie, Head of AMR APAC at Infios, commented on the successful collaboration: “DSL exemplifies how the right automation technology can overcome operational constraints while enabling business growth. This implementation showcases the adaptability of our autonomous mobile robots for 3PLs supporting complex, multi-client environments”. The adoption of AMRs by companies like DSL reflects a broader industry trend towards automation to meet evolving consumer expectations for speed and accuracy, particularly in the booming eCommerce sector.

Buoyed by the initial success of the sortation rollout, DSL Logistics is already looking to the future. The company plans to further its automation journey by piloting additional innovations from Infios, including 3D sortation modules and Layer Picker technology, aiming to achieve even greater performance boosts in its eCommerce fulfilment operations. This forward-thinking approach signals a commitment to continuous improvement and a readiness to embrace cutting-edge solutions to stay ahead in the competitive logistics landscape.