Cabela's

System Summary

Cabela’s is the largest mail-order, retail and internet outdoor retailer in the world. A new distribution center was opened in Wheeling, WV to better service their stores and online customers.

Cabelas Case Study

Business Challenge

  • Provide an ergonomic system for large and heavy products
  • Have the system up and running to meet the peak season of September – December
  • Expanding retail store volume and E-Commerce orders

Key Technologies:Phase 1conveyor

  • Over 25,000 ft. of conveyor
  • 2 Hytrol ProSort sorters (one for retail, one for catalogue)
  • Double-sided sorter at 90 cartons per minute
  • 3 –Level 87,000 square foot Unarco pick module
  • 48,000 square feet of Torbeck mezzanines
  • Belted extendable truck loaders/unloaders in the dock areas
  • High speed Datalogic scanner
  • Mettler Toledo in-line scales

Key Technologies:Phase 2Cabelas

  • 240 position ASAP Exacta Put to Light system
  • BMH conveyor control software and HMI screens
  • 6,000 feet of Hytrol conveyor
  • 2 Hytrol ProSort sorters (ship alone & Put To Light)
  • Gravity extendable truck loaders (shipping)
  • Mecalux rack

ResultsHuman Machine Interface

  • Ability to meet seasonal demand increased throughput: catalogue system achieved 94 cases per minute and ship alone aorter reached 30 cases per minute
  • Decreased transportation costs as orders to the East Coast no longer had to be shipped from Wisconsin or Nebraska
  • Ergonomic handling of product for worker safety and job satisfaction