DHL Supply Chain Japan Strengthens Baycrew’s Growth Strategy With Advanced Automated Storage and Retrieval System

• DHL and Baycrew’s realize a next-generation logistics center by expanding capacity without adding facilities
• The automated solution integrates both B2B and B2C functions in line with future business growth ambitions 

DHL Supply Chain, the global leader in contract logistics, has implemented an Automated Storage and Retrieval System (ASRS) for Baycrew’s, one of Japan’s leading apparel companies, at the Kashiwa-shonan Logistics Center. The implementation supports Baycrew’s growth ambitions by increasing storage capacity and operational efficiency within the existing facility.

Through its long-standing partnership with DHL Supply Chain Japan, Baycrew’s has progressively developed its logistics capabilities to support long-term growth driven by its omnichannel strategy. In 2016, four separate locations were consolidated into the Kashiwa-shonan Logistics Center, creating a centralized logistics operation. Since then, the two companies have continued to strengthen the operation through a series of initiatives, including the deployment of Radio Frequency Identification (RFID) technology in 2020 to improve inventory visibility and operational efficiency, followed by the introduction of automated packing lines for e-commerce shipments in 2024. The new ASRS is the next step in that journey and reflects DHL Supply Chain’s broader approach of deploying proven automation technologies where they deliver measurable operational value and can be scaled to support future growth.

The ASRS combines high-density storage with autonomous robotics to make better use of available warehouse space. Products are stored in compact bins stacked across the system and retrieved by robots that automatically transport them to operator workstations as needed. By reducing travel distances and maximizing vertical storage capacity, the solution increases storage density, improves productivity and creates additional capacity within the existing facility. The system currently manages approximately 10,800 bins using 60 robots.

For inbound operations, robots deliver empty bins to workstations, where operators load products before the bins are automatically returned to storage. For outbound operations, robots retrieve the required inventory and bring it directly to operators for picking and sorting. This goods-to-person approach minimizes unnecessary movement across the warehouse floor, streamlines workflows and helps maintain high productivity as order volumes increase.

Jérôme Gillet, President & CEO of DHL Supply Chain Japan, said: “At DHL Supply Chain, we work closely with our customers to identify and implement innovative solutions that improve productivity, enhance quality, and support long-term growth. Our longstanding partnership with Baycrew’s, together with their strong commitment to innovation, has enabled the successful implementation of this ASRS. This milestone will further strengthen Baycrew’s logistics capabilities and support their future growth.”

In addition to streamlining workflows, the ASRS makes better use of available vertical warehouse space, achieving higher storage density than conventional shelving systems. The result is improved space utilization and additional capacity within the existing facility.

“Logistics is the lifeline of our retail business. Rather than expanding warehouse capacity through additional facilities as business grows, we have consistently worked to create a logistics center that delivers maximum capacity within the smallest possible footprint. Even today, it is still rare within our industry to operate both B2B and B2C logistics from a single distribution center. With the introduction of ASRS, we have further enhanced storage efficiency and productivity while establishing a logistics platform that can flexibly scale in line with business growth without the need for additional facilities. As a result, we are now well positioned to support our anticipated growth trajectory over the next five years,” comments Baycrew’s. “This investment also represents a significant step forward in addressing broader workforce challenges and advancing a more sustainable logistics operation. Looking ahead, together with DHL, we will continue to evolve our logistics capabilities and drive supply chain innovation. Beyond operational excellence, our ambition is to build a supply chain that minimizes unnecessary production, inventory, and transportation, ultimately creating greater value for our customers and supporting a more sustainable future.”

The Baycrew’s implementation reflects DHL Supply Chain’s approach to automation: identifying proven technologies, working with robotics providers and adapting solutions to specific customer and operational requirements. By combining operational expertise with automation and digital technologies, DHL Supply Chain helps customers improve efficiency, optimize available warehouse space and create logistics operations that can scale in line with business growth.

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At a Glance:

• DHL Supply Chain Japan has implemented an Automated Storage and Retrieval System (ASRS) for Baycrew’s at the Kashiwa-shonan Logistics Center in Japan.
• The solution combines high-density storage, autonomous robotics and goods-to-person processes to increase capacity within the existing facility.
• Approximately 10,800 storage bins are managed by a fleet of 60 robots, helping optimize available warehouse space and reduce unnecessary movement within the operation.
• ·The project builds on previous digitalization and automation initiatives, including RFID-enabled inventory management and automated packing solutions.
• The implementation reflects DHL Supply Chain’s approach of applying proven automation technologies to improve efficiency, create scalable logistics capacity and support future business growth.