Summary
Key results
Automated operations restored using existing components
Expanded sorting capacity for more product variants
One partner needed for a large-scale move
For a global fashion retailer operating thousands of stores and online sales across dozens of markets, warehouse automation directly affects operational continuity and order fulfillment. When a sorting line is moved to a new site, errors in dismantling, transport, installation, or commissioning can delay the restart of operations and disrupt daily logistics.
The organization needed to relocate and expand an existing sorting line built from roller conveyors, belt conveyors, and robotic stations. After a period of manual work, the priority was to restore automated operations as quickly as possible while adapting the line to the new facility and increasing the number of storage racks and product variants the system could handle. Another important objective was to reuse existing system components where possible, reducing the need for a full new system investment.
The project required one trusted partner able to manage the full scope, from engineering and material procurement to on-site coordination, installation, and commissioning. Sii Poland was well positioned for this role thanks to its hands-on industrial engineering expertise, as well as the ability to scale assembly support and enable fast, reliable commissioning.
Multidisciplinary team for end-to-end delivery
Sii Poland was responsible for relocating and expanding the existing warehouse sorting line and preparing it for operation in the new facility. Around 30 specialists contributed to the project, covering mechanical, electrical, automation, hardware design and assembly, project management, procurement, material management, legal and PMO roles.
Their work covered the full delivery path: from technical preparation, inventory and material organization to dismantling, transport, installation, integration, testing, and commissioning. It also included the reuse of existing components and the preparation of new elements required for the expanded line.
The scope of work included:
- Dismantling and transporting conveyor and sorting line components from the previous location
- Preparing hardware design for the new setup and adapting the line to the requirements of the new facility
- Purchasing new conveyor components and manufacturing of the new control cabinets
- Extending selected work zones and conveyor sections, including packing line areas and conveyor sections leading wastepaper to the baler
- Installing additional functionality, including notifications about rack fill levels
- Performing mechanical and electrical installation of the conveyor system and robotic stations
- Installing and integrating robotic stations used for stacking and tying containers before transport to target stores
- Commissioning the relocated system, including functional testing and maintanence of the transferred installation
- Integrating the line with the existing IT infrastructure and Warehouse Management System (WMS)
- Supporting data flows related to container movement and integrating production email notifications
- Coordinating on-site work as the main contractor, including work schedules, teams, safety requirements, and acceptance activities
- Organizing procurement and material management, including installation materials, replacement parts, conveyor elements, motors, control cabinet equipment, and conveyor belts
Due to the scale of the project and the need to restart selected areas progressively, the work was organized in phases. Individual zones were launched step by step, with part of the work carried out in day and night shifts during selected stages of the project.
Restored automation, higher capacity, and controlled rebuild execution
The client regained automated warehouse operations after temporarily switching to manual processes. By relocating, rebuilding, and commissioning the existing sorting line in the new facility, Sii Poland helped return to automated processing without replacing the entire system from scratch. The reuse of existing components, supported by preventive replacements and new elements where needed, reduced the investment effort while keeping the system aligned with the requirements of the new site.
The expanded line also improved operational capacity. Extended work zones, additional conveyor sections, and new functionality for rack-fill notifications helped the system handle more storage racks and product variants. With the line integrated into the existing IT environment and Warehouse Management System (WMS), warehouse teams could continue working with data on container movement within their operational setup.
A single accountable partner made the rebuild easier to control. Sii coordinated engineering, procurement, materials, on-site teams, safety requirements, installation, testing, and commissioning across the full project scope. This reduced fragmentation during a complex move and gave the organization one delivery partner responsible for bringing the line back into automated operation.
Key results
- Sorting line expanded to support more storage racks and product variants
- Automated warehouse operations restored after a period of manual work
- Existing system components reused in the new facility
- End-to-end rebuild coordinated by a multidisciplinary Sii team, including procurement and on-site work