Renault Group Slashes Order Time from 120 to 15 Minutes

To speed up spare parts logistics, Renault Group turned to the Exotec Skypod system—an elegant AS/RS that powered a reduction in order processing time from 120 minutes to just 15.

The Challenge

Renault Group faced a number of major challenges in managing its spare parts logistics in Europe:

• Fragmented distribution system — warehouses were organized by part type instead of region, creating inefficiencies
• No dedicated warehouse for France — limited capacity to meet national demand, which represents 37% of DLPA’s operations
• Outdated systems — aging equipment and technology hindered customer service quality and innovation

To overcome these challenges, Renault Group reorganized its spare parts warehouse network in France, focusing on centralizing operations and customizing sites for specific market needs. At the center of this effort was the Villeroy facility, which was fully modernized with the Skypod system as its core technology and designated as the main distribution center for the French market.

Additional Automation Integrated

With the Skypod system as the core technology, Exotec integrated a wide range of additional solution for end-to-end automation including:

• Suite of specialized machines, including carton forming and closing systems, packing list and RFID label printers, a wrapping machine, and 30 ergonomic grippers — all designed to boost speed and accuracy
• Dealer label printers at picking stations improve inventory traceability and stock management.
• A built-in trashline system at injection stations ensures efficient waste handling and a cleaner workspace

Key Results

Game-Changing Performance

• Over 5,000 lines picked per hour with just 14 Skypod system operators
• Order processing time dropped dramatically — from 120 minutes to just 15 minutes, enabling faster fulfillment
• Ability to store and pick over 1.6 million items in just 3,450 m² (37,300 ft²) — a little more than half the size of a football field

Operational Stability & Cost Savings

• Centralized over 80% of French operations into a single facility thanks to Skypod system’s ability to manage omnichannel fulfillment and seamlessly adapt to dynamic order demands

Elevating Customer Service

• Orders placed as late as 5:30 PM are delivered by 8:00 AM the next day — a major win for responsiveness and convenience
• Achieved a customer satisfaction rate exceeding 99.7%, reinforcing the reliability and speed of fulfillment

“Keeping to the schedule and achieving our ramp-up curve were major challenges. We are satisfied with the results achieved so far and are preparing to finalise the organisational transformation around this new facility.”