Case Study: Cabela's

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  Cabela's Case Study
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About Cabela's

Cabela’s has great products for people who enjoy an outdoor lifestyle by delivering innovation, quality, and value. Started in 1961, the company has become the largest mail-order, retail, and internet outdoor outfitter in the world. With major distribution centers in Nebraska and Wisconsin, Cabela’s turned to Bastian Material Handling to help them automate a brand new distribution center in Wheeling, West Virginia.

Cabela's Distribution Center

Challenges facing Cabela's

Cabela's Retail Store

  • Since this was a new facility, Cabela’s had to hire and train new personnel, set up operations and processes, and receive and inventory product.
  • The building process was delayed, so all phases of installing material handling equipment were in turn delayed. However, Cabela’s still needed to be up and running for their peak season of September – December.
  • Cabela’s needed to optimize throughput in order to meet growing customer demand.
  • An ergonomic system needed to be implemented for the comfort of employees.
  • Close coordination with the County was required to satisfy manning and site investment requirements.

Key Technologies: Phase 1

Cabela's

  • Over 25,000 Ft. of conveyor
  • 2 Hytrol ProSort Sorters (one for retail, one for catalogue)
  • Double-sided Sorter at 90 Cartons Per Minute (CPM)
  • 3 –Level 87,000 square foot Unarco Pick Module
  • 48,000 square feet of Torbeck Mezzanines
  • Belted Extendable Truck Loaders/Unloaders in the dock areas
  • High Speed Datalogic Scanner
  • Mettler Toledo In-Line Scales

Key Technologies: Phase 2

Cabela's

  • 6,000 feet of Hytrol Conveyor
  • 2 Hytrol ProSort Sorters (Ship Alone & Put To Light (PTL))
  • 240 Position Pick to Light (PTL) System by ASAP Automation
  • Gravity Extendable Truck Loaders (Shipping)
  • Mecalux Rack
  • Bastian Material Handling Warehouse Control System (WCS) Software and HMI Screens

Results

  • The ability to meet seasonal demand increased throughput: Catalogue System achieved 94 CPM and Ship Alone Sorter reached 30 CPM
  • Decreased transportation costs as orders to the East Coast no longer had to be shipped from Wisconsin or Nebraska
  • Ergonomic handling of product for worker safety and job satisfaction