{"id":4498,"date":"2025-11-05T17:48:22","date_gmt":"2025-11-05T21:48:22","guid":{"rendered":"https:\/\/pixels360.locusrobotics.com\/?p=4498"},"modified":"2025-11-05T17:49:28","modified_gmt":"2025-11-05T21:49:28","slug":"ss-activewear-scale-warehouse-robots","status":"publish","type":"post","link":"https:\/\/locusrobotics.com\/blog\/ss-activewear-scale-warehouse-robots","title":{"rendered":"How S&S Activewear Scaled Smarter with Warehouse Robots"},"content":{"rendered":"\t\t
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November 05, 2025<\/div>\n

How S&S Activewear Scaled Smarter with Warehouse Robots<\/h1>\n \n

\n \"Author\n Mary Hart<\/span>, Sr. Content Marketing Manager<\/span>\n <\/p>\n <\/a>\n <\/div>\n

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When growth outpaces your floor, even the best operations teams feel the strain. For\u00a0<\/span>S&S Activewear<\/span><\/b><\/a>, a leading distributor of\u00a0imprintable\u00a0apparel and accessories with 18 distribution centers across North America, the challenge was how to keep up with rising demand without overextending their workforce.<\/span>\u00a0<\/span><\/p>

\u201cWe were growing quickly, but it just wasn\u2019t sustainable to keep adding more employees,\u201d said\u00a0<\/span>Cole Lohman<\/span><\/b>, Director of\u00a0Automation at S&S Activewear. \u201cWe needed a technology solution that could help our productivity.\u201d<\/span>\u00a0<\/span><\/p>

That solution arrived with the 2024 acquisition of\u00a0<\/span>alphabroder, a company\u00a0that was\u00a0already thriving with Locus Robotics. The success Lohman\u2019s team saw\u00a0with warehouse automation\u00a0made the next step clear\u00a0that\u00a0it was time to bring robotics to S&S.<\/span>\u00a0<\/span><\/p>

From Stock Chasers to Smart Zones<\/span><\/b>\u00a0<\/span><\/h2>

Before automation, S&S relied on stock chasers and batch picking\u00a0to send\u00a0associates across the floor to fulfill orders. Associates that used the stock chasers needed to be certified, which typically took 2 days to complete, but then there was an\u00a0additional\u00a02 to 3 months of time for the driver to feel comfortable and proficient.\u00a0<\/span>\u00a0<\/span><\/p>

\u201cUsers were picking from one side of the building to the other,\u201d recalled\u00a0<\/span>James Hillier<\/span><\/b>,\u00a0Regional Director of Operations at S&S Canada.\u00a0\u201cIt took a long time to finish everything.\u201d<\/span>\u00a0<\/span><\/p>

The shift to automation was immediate. \u201cIt was magic,\u201d said\u00a0<\/span>Randy Hazelwood<\/span><\/b>,\u00a0Shipping Supervisor at S&S Canada. \u201cWith Locus coming in, it was a fast changeover.\u201d<\/span>\u00a0<\/span><\/p>

The team transitioned to\u00a0<\/span>zone picking<\/span><\/b>, where associates stayed in defined areas while Locus\u00a0Robots\u00a0moved orders between zones. \u201cThat\u2019s enabled our teams to travel less and pick more,\u201d Hillier said. The result\u00a0was a\u00a0<\/span>25% improvement in throughput<\/span><\/b>\u00a0and a jump from\u00a0<\/span>48 lines per hour to 70\u201375 lines per hour<\/span><\/b>.<\/span>\u00a0<\/span><\/p>

Even more telling, the Vaughan, Ontario site now holds the top productivity ranking across the S&S network after just three months of running Locus Robotics.<\/span>\u00a0<\/span><\/p>

A Lesson in Speed and Simplicity<\/span><\/b>\u00a0<\/span><\/h2>

S&S\u2019s first Locus deployment\u00a0met and exceeded their expectations.<\/span>\u00a0<\/span><\/p>

\u201cOur integration took only\u00a0<\/span>49 days<\/span><\/b>\u00a0from green light to go-live,\u201d said\u00a0<\/span>Mitchell Bluford<\/span><\/b>,\u00a0Sales\u00a0Executive at Locus Robotics. \u201cThat\u2019s one of the fastest we\u2019ve ever seen.\u201d<\/span>\u00a0<\/span><\/p>

The implementation itself was remarkably smooth. \u201cBringing on new technologies can be challenging at times,\u201d Lohman said. \u201cThis one was a little bit boring\u00a0as\u00a0it went as expected, with no real stressors at all.\u201d<\/span>\u00a0<\/span><\/p>

The facility\u00a0didn\u2019t\u00a0need to change its layout or retrain the team from scratch. \u201cThe\u00a0robots worked within our existing warehouse,\u201d Lohman explained. \u201cLocus made the integration incredibly easy.\u201d<\/span>\u00a0<\/span><\/p>

That ease\u00a0translated\u00a0into real workforce benefits. \u201cThe intuitive interface\u00a0cut\u00a0training time in half,\u201d Lohman\u00a0continued. \u201cStock chaser certification could take up to three months before\u00a0and\u00a0now our new associates are productive in days.\u201d<\/span>\u00a0<\/span><\/p>

Breaking Records and Building Balance<\/span><\/b>\u00a0<\/span><\/h2>

Warehouse automation quickly changed more than just metrics\u00a0at S&S Activewear. \u201cWe completed and shipped\u00a0<\/span>23,000 lines in one day<\/span><\/b>,\u201d Hillier shared. \u201cAfter Canada Day, we even hit an hour with over 3,000 lines shipped.\u201d<\/span>\u00a0<\/span><\/p>

During their busiest week of 2025, the team\u00a0fulfilled\u00a0<\/span>over 100,000 lines,<\/span><\/b>\u00a0without the long shifts that used to define peak season. \u201cLast year, we\u00a0would have\u00a0been working 12- to 14-hour days,\u201d Hillier said. \u201cNow we\u2019re finishing in eight to nine hours, and people are getting more balance at home.\u201d<\/span>\u00a0<\/span><\/p>

For S&S associates, that shift has been tangible. \u201cIt\u2019s so efficient that we finish on time no matter how much work there is,\u201d Hazelwood said. \u201cMaking customers happy is our top priority, and the system makes that easy.\u201d<\/span>\u00a0<\/span><\/p>

The ergonomic gains were just as important. \u201cWorking with\u00a0the robots\u00a0is less strenuous,\u201d said\u00a0<\/span>Benjamin\u00a0DePrisco<\/span><\/b>,\u00a0Safety Specialist. \u201cIt\u2019s a lot better ergonomically,\u00a0and we\u2019ve seen a reduction in ergonomic reports compared to when we used stock chasers.\u201d<\/span>\u00a0<\/span><\/p>

A Data-Driven Path to Continuous Improvement<\/span><\/b>\u00a0<\/span><\/h2>

Beyond productivity, S&S uses the\u00a0LocusHub\u00a0platform to fine-tune performance. \u201cWe\u2019re matching how we staff and position our employees to the capabilities of\u00a0the\u00a0robots,\u201d Lohman said. \u201cLocus provides a lot of good data to see how efficient we\u2019re being.\u201d<\/span>\u00a0<\/span><\/p>

Hillier agrees: \u201cLocusHub\u00a0reporting is very intuitive. There are so many ways to use it to help run your business.\u201d<\/span>\u00a0<\/span><\/p>

That focus on continuous improvement is paying off fast. \u201cWe\u2019re building toward hitting our ROI in a very short amount of time,\u201d Lohman said. \u201cAnd Locus has been a great partner\u00a0that is\u00a0very supportive of ongoing improvements.\u201d<\/span>\u00a0<\/span><\/p>

Today, S&S runs Locus\u00a0Robots\u00a0in 10 facilities across the U.S. and Canada, with\u00a0<\/span>four more<\/span><\/b>\u00a0in the pipeline. The company continues to expand both its automation footprint and its data-driven mindset\u00a0to scale\u00a0smarter, not harder.<\/span>\u00a0<\/span><\/p>

For S&S Activewear, automation has meant more than efficiency gains.\u00a0It means\u00a0balance for associates, consistency for customers, and scalability for the business.<\/span>\u00a0<\/span><\/p>

\u201cWe\u2019ve set records for productivity, and we\u2019re still improving,\u201d said Bluford. \u201cThat\u2019s what makes this partnership special \u2014 it doesn\u2019t end at go-live.\u201d<\/span>\u00a0<\/span><\/p>

See how S&S Activewear\u00a0improved fulfillment efficiency.\u00a0<\/span><\/b>Watch the full case study video\u00a0and read the written case\u00a0study.<\/span><\/a>\u00a0<\/span><\/p> <\/div>\n <\/div>\n <\/section>\n <\/section>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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Discover how S&S Activewear transformed warehouse productivity with Locus Robotics to boost throughput 25%, cut training time in half, and achieve record fulfillment speed, balance, and scalability.<\/p>\n","protected":false},"author":5,"featured_media":4497,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":true,"inline_featured_image":false,"footnotes":""},"categories":[4],"tags":[69,73,70,74],"solution_type":[],"industry_type":[42],"country":[],"post_folder":[],"class_list":["post-4498","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-article","tag-decision-making","tag-fulfillment","tag-safety","tag-warehouse-automation","industry_type-retail"],"acf":[],"yoast_head":"\nHow S&S Activewear Scaled with Warehouse Robots<\/title>\n<meta name=\"description\" content=\"Discover how S&S Activewear scaled their warehouse productivity with robots to achieve record fulfillment 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