Four sites, one standard needed
Two Swedish warehouses, one in Poland and one in the USA each ran their own way. Without a shared system, best practice couldn't travel between sites and every improvement had to be reinvented locally.
Hultafors Group runs a portfolio of tools and workwear brands from four warehouses spread across Sweden, Poland and the USA. The challenge wasn't one warehouse; it was making four of them, on two continents and in three time zones, run their warehouse automation on the same logic.
In this video:
Nicklas Axell, Group Logistics Director
Dawid Ciesielski, Site Manager Poland
“Bitlog is incredibly easy to use. I haven't come across systems that are as simple and user-friendly.”
Hultafors Group is a European tools and workwear company built around brands that tradespeople know well, including Snickers Workwear, Hultafors Tools, Solid Gear, Hellberg Safety and CLC Work Gear. Those brands ship from four warehouses: two in Sweden (Nässjö and Olsfors), one in Poland (Szczecin) and one in the USA (Milwaukee, Wisconsin).
Each site serves a different mix of customers, from small, frequent European deliveries to large orders for North American retailers. As the group expanded, running each warehouse on its own logic stopped scaling, and the operation needed a single system that could handle every site without flattening what made each one different.
Growth had left Hultafors Group running very different operations under one roof, and no single system tied them together.
Two Swedish warehouses, one in Poland and one in the USA each ran their own way. Without a shared system, best practice couldn't travel between sites and every improvement had to be reinvented locally.
European sites handle a steady stream of small deliveries; the US site fills large orders for major retailers. The warehouse needed to switch between those rhythms without slowing down or bolting on a separate process for each.
Hultafors Group wanted to run AutoStore, conveyors and value-added services like custom sizing and logo printing. The old setup couldn't orchestrate automated hardware and manual work in a single, coordinated flow.
Hultafors Group chose Bitlog WMS because it could do the hard part, coordinating automation and manual work in one flow, without being hard to use on the floor. In Poland, Bitlog WMS orchestrates AutoStore, transport systems and dispatch as a single operation, consolidating orders and running customized value-added services in the same flow. It was the site's first AutoStore installation, and Bitlog was the brain that tied the robots, conveyors and picking together.
The same system then scaled to the group's other warehouses. In the USA, the Milwaukee facility replaced three previous warehouses and moved onto Bitlog WMS alongside the rest of the group, so four sites now run on one platform. In Sweden, the smaller Nässjö and Olsfors warehouses use Bitlog's mobile app to prioritize picking. What sealed it was that the same system worked for a fully automated site and a lean manual one without becoming two different products.
Across its sites, Hultafors Group runs Bitlog WMS, tuned to each warehouse's mix of automation and manual work.
In Poland, Bitlog WMS coordinates AutoStore, conveyors and dispatch as one flow, so goods-to-person robots and manual steps work off the same plan.
Learn moreOrders are consolidated and run through customized value-added services (VAS) like sizing and logo printing without leaving the picking flow.
Learn moreAt the Swedish sites, pickers work from Bitlog's mobile app, which prioritizes what to pick next so smaller teams stay fast.
Learn moreOne WMS installation runs across four warehouses and connects to the group's ERP and automation systems, so every site works to the same standard.
Learn more“Having every warehouse on the same system means what we learn at one site actually reaches the others.”
The Szczecin site was the first AutoStore installation in Poland, and standing up new automation is where projects usually stall. The hard part isn't the robots; it's making the robots, the conveyors, the value-added services (VAS) and the manual pickers all work off one plan instead of four disconnected ones.
Bitlog WMS ran as the brain across all of it, consolidating orders and sequencing automated and manual work in a single flow. That coordination is what took the site from around 1,000 to 3,000 order lines a day.
“Three days after go-live, the warehouse was noticeably faster and the quality of the work had gone up.”
The move to Bitlog WMS shows up in four numbers, and each one points back to a specific operational change on the floor.
The Szczecin site tripled its daily throughput, from around 1,000 to 3,000 order lines, by orchestrating AutoStore and manual work in one flow.
One system holds together an operation that spans two continents, with the Milwaukee facility consolidating three previous warehouses onto Bitlog.
Sweden, Poland and the USA run on the same platform, so a process that works at one site can move to the others.
Hultafors Group's warehouse automation now runs as one operation instead of four separate ones: four warehouses in three countries on two continents, all in one Bitlog WMS. Picking errors were all but eliminated, and the Poland site increased pick speed by 200% and tripled its daily capacity from 1,000 to 3,000 order lines by orchestrating AutoStore, conveyors and manual picking in a single flow.
Because the same system runs a fully automated site and a lean manual one, best practice travels between Sweden, Poland and the USA instead of being reinvented locally. It's a system the floor found easy to learn, which is what let the group scale it across two continents.
With every warehouse on one platform, Hultafors Group can keep adding sites, automation and services without adding a new way of working each time.
Poland went from around 1,000 to 3,000 order lines a day by orchestrating AutoStore and manual work together, not by adding a parallel process for the robots.
Growth only works if people can keep up with it. New pickers get productive fast, so scaling the team for peak never becomes the bottleneck.
Pick speed in the Poland warehouse is up 200% while picking errors have been all but eliminated, so speed didn't come at the cost of quality.
How Care of Carl went from pen and paper to 40% more efficient warehousing.
Hultafors Group runs four warehouses in three countries, on two continents and multiple time zones.
12-month picking goal reached in four months. Rapid growth with new automation on Bitlog WMS.
Thirty minutes with our team. We'll show you the modules running together, against the questions your operation actually asks.