Case:
Internetstores
Efficient solution for returns management
Internetstores is the world’s leading bicycle retailer. Through the e-commerce platforms fahrrad.de, Brügelmann, Bikester, Probikeshop, Campz and Addnature, it offers 130,000 products and 1,300 different brands. Its strong online business is complemented by local stores in Germany, Sweden and France, as well as a growing network of mobile service partners. The Internetstores Group is part of SIGNA Sports United and has around 800 employees in Stuttgart, Berlin, Lyon and Stockholm.
As Internetstores delivers directly to end customers, technically complex products such as bicycles must be prepared and pre-assembled before shipping. The customer can then assemble the new bicycle in just a few simple steps. As early as 2016, demand for bicycles was high and the first assembly line was installed at Internetstores in Gehrde. The solution was developed through close cooperation between Internetstores and OCS. The system features a specially designed product carrier for handling all assembly steps—from children’s bicycles to advanced e-bikes.
Need
The first OCS system in Gehrde has been expanded several times in recent years. Thanks to the flexible and modular conveyor system, it has been smoothly adapted to meet steadily increasing demand. A key element in e-commerce is handling returns efficiently and cost-effectively. Until 2019, returns at Internetstores were handled in Esslingen, but based on previous experience with the OCS Overhead Conveyor System in Gehrde, Internetstores decided to install an additional OCS system to manage returns. Location: Stuttgart-Untertürkheim.
Solution
The solution was designed specifically to fit within the existing facility. Due to the large number of units to be handled, the solution became a two-level system. The procedures for returns management are similar to the handling of new goods. In addition to the product-handling process, a photo studio was also integrated into the system.
The return boxes are opened at two unpacking stations and the bicycles are hooked onto the OCS system. The product carrier has a similar structure to the assembly line in Gehrde. Transport takes place automatically from the unpacking stations to the assembly stations and then to the next level via OCS vertical conveyors. After assembly/inspection, the bicycles are transported to the photo studio and from there to the packing stations. The entire OCS system is fully automated and connected to the customer’s own ERP system, enabling precise tracking of the products throughout the entire process.
An oil-free, clean and quiet system
Ergonomic and Space-Efficient
Safe in accordance with the ATEX Directive
Can run back and forth at different speeds
Results after installation
From 2020 onwards, it was no longer economically justifiable to handle the volume of returns manually. Returns management therefore needed to be automated. In addition to significantly improved cost efficiency, the process is now fully traceable. Faster handling means that goods are reintegrated into the value chain much earlier.
“By using the OCS overhead conveyor system, the workflow has been optimised and made more efficient. We can now focus on the product and no longer need to worry about separate handling of parts (delivery of parts to the workstations). In addition, the system makes it possible to match different types of bicycles with the appropriate employee based on complexity. This is controlled by the Internetstores ERP. In this way, we achieve a perfect balance between quality and quantity.”
– Eduard Jesser, Head of Returns, Internetstores.
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