Lecot invests in further expansion of a high-tech distribution center

After four generations, by 2023, Lecot has grown into the largest national player in hardware, fixtures, construction hardware, tools, and personal protective equipment. Since its inception and the period after the Lieven Santens family took over Lecot in 1995, much has changed, but Lecot's large range is well-known everywhere: with over 110,000 ordered products, 40,000 of which are immediately available, anyone in the construction sector will undoubtedly find what they're looking for. Lecot is heavily investing in an omnichannel customer experience combining digital channels, a widespread network of branches, and on-site deliveries. The driving force behind this rapidly growing company has always been its state-of-the-art logistics operation.

To continue to guarantee further growth with strong customer service, over the next three years the company will invest in strongly advanced, flexible, and modular automation of logistics.

Logistic engine

"In 2000, we achieved a turnover of 26 million euros with 4 branches. However, we operated with old-fashioned logistics, outdated IT, without a website or online presence. By 2023, we can boast a financially very healthy firm, with 80 branches - 4 of those in the Netherlands, a turnover of 267 million euros, achieved by about 750 employees, well-functioning modern logistics, and a large share of internet sales." (says Lecot).

Around the turn of the century, the organisation realised that superior logistics performance was necessary to continue to support the growth of its activities. The company then asked the logistics consulting firm Logflow to review its logistics activities. This exercise resulted in a master plan in early 2002, which led to the GO LIVE of a new distribution center on the site in Heule in 2006. A well-thought-out layout and state-of-the-art WMS control were already the logistical backbone of the semi-manual operations. Through complementary operations with the distribution center in Maaseik, Lecot was able to grow quickly: both digitally in terms of e-commerce and physically with around 5 additional branches each year.

A continuous evaluation of that master plan led in 2013 to the expansion of the distribution center in Heule with a high-bay warehouse (18m) for bulk storage. Over the years, several WMS optimisations followed.

Master Plan Logistics 4.0

Recently, a completely new logistics master plan was drawn up by Logflow, which made clear that advanced automation in the form of a fully automated bin warehouse (AS/RS shuttle) for small goods, combined with semi-manual operations with even stronger advanced WMS logics for other product groups (pallet goods, hand tools, long goods, ugly, ...) was necessary. In this context, a new WMS-package was integrated into both distribution centers in Maaseik and Heule in 2020-2021. The solution of C&W logistics was chosen. During the implementation, consideration was already given to the integration of an AS/RS shuttle system in the near future.

In 2022, Lecot had the opportunity to acquire the 13,000m² site of its neighbors (formerly Hoorens Printing). This opportunity ensures the long-term anchoring of Lecot on the site in Heule. With the fully sketched master plan concept, Lecot can achieve multiple growth on the site. Subsequently, Logflow worked out a fine definition of the logistics concept during the Conceptual Design study. Both the short and long term layouts were fully developed, with great attention paid to the phasing so that the continuity of the current operations can be guaranteed. A building was then developed around the concept, in cooperation with the architectural and engineering firm DBG (D'hondt-Beyens-Goesaert) from Kortrijk.

The foundations of the concept are ready to plug in 'logistics 4.0' technologies over the coming years. For instance, the reception process was conceived to receive the 110,000 different references easily without requiring product knowledge, and the warehouse operator will be assisted via artificial intelligence. In addition, the ergonomic set-up of workstations was greatly considered in the design. Moreover, a sorting installation is planned to easily sort out both collection orders, branch restocking and transporter consignments, which can later be transported by autonomous forklifts (AGV/AMR).

Start of sustainable partnership with KNAPP

During an extensive selection process, KNAPP was chosen as the final partner for the automatic system. The heart of the installation will be a triple-deep goods-to-person system with KNAPP's OSR™ EVO shuttle technology.

KNAPP OSR^™ EVO shuttle (left), KNAPP Pick-it-Easy station (right)

In the first phase, two 80-meter-long aisles with a height of 16 meters are being erected, good for 58,000 bin locations. In the long term, the storage system can triple to 174,000 bin positions. The 74 OSR^™ EVO shuttles provide the supply and removal of bins to various ergonomic Pick-it-Easy workstations. This station is equipped with height-adjustable platforms and light grid systems to visually assist operators during order picking. Furthermore, the shuttle system will not only be used as a storage medium but also as a buffer. For example, orders can be buffered between order picking and packaging. Afterwards, a sorting installation with space for more than 100 destinations ensures that orders can be easily sorted out in the future.

By optimising height utilisation and using a condensed storage technique, Lecot can minimize the building footprint and contribute to a sustainable solution.

The contract between Lecot and KNAPP was signed at the end of February 2023, marking the start of a sustainable partnership between the different parties. It is expected that the new system will be fully operational by the summer of 2025.

The project team from Lecot – Logflow – Knapp.

(from left to right: Hans-Georg Rainer (KNAPP), Simon Popelier (Logflow), Stefaan Verhoyen (Lecot), Werner De Swaef (KNAPP), Wolfgang Skrabitz (KNAPP), Philippe De Veyt (Lecot), Eric Vandenbussche (Logflow), Pieter Morisse (Lecot))