Human-Centered Warehouse Automation at EssilorLuxottica

EssilorLuxottica’s North American hub in Atlanta handles an extensive portfolio that includes Ray‑Ban, Oakley, and retail brands such as Sunglass Hut and LensCrafters. Although product dimensions are uniform—most frames share similar size—the SKU count runs into thousands because each color, style, and lens option creates a separate unit. The facility supports wholesale, e‑commerce, direct store replenishment, and international exports. This high‑SKU, low‑variance environment forces precise inventory control, rapid wave planning, and real‑time labor orchestration. The warehouse also leverages mixed media racking and forward‑picking aisles to accelerate order fulfillment.

Slotting relies on an Excel model that ingests AI‑enhanced demand forecasts. Instead of complex algorithms, weekly forecast data drives storage decisions, updating locations each week to match seasonal peaks for sunglasses, goggles, or accessories. Fast‑moving items receive larger, higher‑density slots; slower SKUs are placed in smaller spaces with only a week’s supply. Weekly adjustments also consider labor availability, ensuring that slot changes do not overload the workforce. This dynamic method balances moving costs against optimal placement, ensuring efficient use of limited storage while maintaining labor productivity.

The automation roadmap starts with a macro business case that pinpoints picking, packing, or sortation bottlenecks before selecting technology. EssilorLuxottica installed dense AMR‑compatible racking before robot deployment, smoothing the transition to autonomous mobile robots. Pilots begin in low‑risk zones with built‑in recovery plans, and every design keeps humans central. Equipment reduces cognitive load and eliminates ergonomic hazards, such as heavy overhead lifts. The partnership with automation providers includes service level agreements that guarantee uptime and rapid issue resolution. By combining AI forecasting, flexible slotting, and human‑centered automation, the company creates a resilient, scalable warehouse that supports its global eyewear empire.