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JOHN LEWIS PARTNERSHIP
AUTOMATED DISTRIBUTION CENTRE

Logistex partnered with the John Lewis Partnership to transform the former well known supermarket brand site at Fenny Lock into a state-of-the-art, fully automated distribution centre. Tasked with improving operational efficiency, scalability and sustainability, Logistex delivered a seamless integration of multiple advanced technologies – all within a live operational environment.

FEATURES

  • 60 HAI Robotics AMRs for tote storage & retrieval

  • 100,000+ tote racking locations

  • Locus Robotics integrated on multi-level pick tower

  • 9 Pick to Light stations achieving 1,500+ units/hour

  • 5 printer & bagging machines for efficient order dispatch

  • LWS Reflex WES controlling all material handling equipment

  • Legacy conveyor reuse to reduce waste and cost

THE CLIENT'S BRIEF

The John Lewis Partnership required a highly automated, integrated solution for the previously manual operation to meet increased online demand, reduce manual intervention, and enable rapid throughput. The project also had to be delivered in a live environment, minimising operational disruption while reusing parts of the original infrastructure to support environmental goals.

THE LOGISTEX SOLUTION

The Fenny Lock transformation was delivered in a two-phase automation strategy, expertly designed and integrated by Logistex to meet the evolving operational needs of John Lewis Partnership.

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Phase 1 focused on deploying Logistex’s powerful Warehouse Execution System (WES), LWS Reflex, to orchestrate the movement of goods and data across the site. Reflex was integrated with legacy conveyors, new automated bagging machines, and a fleet of Locus “Origin” robots operating on the pick tower. This intelligent system enabled real-time control and seamless coordination across multiple picking zones—dramatically improving throughput, order accuracy, and visibility.

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Phase 2 introduced an advanced Tote-to-Person (TTP) picking solution, with a fleet of 60 HAI Robotics HAIPICK Autonomous Mobile Robots (AMRs) and HAIPORT Workstations. These robots retrieve totes from a high-density storage area containing over 100,000 tote locations, transporting them directly to workstations for efficient, ergonomic picking. This flexible and scalable solution significantly boosted storage efficiency and reduced picker travel time.

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Working collaboratively with JLP and HAI Robotics, Logistex delivered a fully integrated, modular solution that enables faster fulfilment, reduces labour dependency, and allows for future expansion—all while maintaining live operations throughout the installation.

ACHIEVEMENTS

  • More than £1m in Productivity and Consolidation Savings during the first 4 months of go-live

  • 140 per hour - the number of units a Partner can pick using Hai Robots, nearly 3 times faster than a manual solution

  • 90% reduction in stock putaway hours, with stock straight from receiving into robotics

  • >1,500 units/hour processed through Pick to Light

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