FKI Logistex completes expansion project for The Forzani Group

OSHAWA, Ont. — FKI Logistex has completed a large project with The Forzani Group, Canada’s largest retailer of sporting goods, by expanding Forzani’s existing distribution centre (DC) in Toronto. FKI Logistex added a new put module and routing sortation system to increase the facility’s capacity and allow Forzani to serve more stores nationwide.

In 2003, FKI Logistex installed an automated material handling system for Forzani that included a put-to-light module, a conveyor system and a UniSort IV shipping sorter. The system was designed to be expandable to support Forzani’s projected growth by including a mezzanine level, which now houses the new put module.

“The expansion of our DC is critical to keeping our stores stocked with a broad selection of sports and outdoor equipment and apparel,” said Keith Lambert, senior vice-president of Supply Chain and Merchandise Management, The Forzani Group. “Working with FKI Logistex to optimize our distribution operations and accommodate our growth has been invaluable to Forzani’s success in our supply chain strategy.”

FKI Logistex provided Forzani with an additional order fulfillment system, which includes EASYpick Put-to-Light software and Trak3 Put-to-Light hardware. The expansion also includes the implementation of quad-directional Accuzone right-angle transfers, which enable the module to sort into four separate zones instead of two, as in the original design. The put-to-light system requires only one light display for each shipping destination, instead of one for every product SKU, as in a pick-to-light system. With fewer displays, the system is designed to service a wide range of products efficiently, making it ideal for Forzani, which ships a large number of SKUs to many locations. FKI Logistex also reworked the infeed and discharge lines to service the new put module, and installed a slapper line to offset full-case picking.

“FKI Logistex has fostered a substantial portfolio of long-term partnerships with major retailers,” said Steve McElweenie, vice-president and general manager of FKI Logistex Canada. “By providing expandable automated material handling systems, FKI Logistex offers its customers the flexibility to scale operations for future growth while maintaining efficiency.”

FKI Logistex completed installation on a six-week schedule, and the new system went live in June.