Construction of the new distribution center

Increasing product demand resulted in the need to expand the warehouse locations for flat goods, shoes, ties and accessories. HUGO BOSS selected Filderstadt near Stuttgart as the preferred location for its new distribution center.

io developed a new flat-packed goods distribution center for HUGO BOSS, integrating IT with a highly automated logistics design. They designed the facility together with the client, based on economic feasibility studies and analyses of requirements and applications. io also provided overall project management for the whole range of planning, tendering and implementation of logistics and IT projects.

Joint solutions for logistical challenges

HUGO BOSS’ range of flat goods are order-picked, packed and shipped in the new central distribution center. This is a facility of impressive dimensions, spanning an area of 23,500 m2. The centerpiece is a shuttle warehouse with a capacity of approximately 400,000 boxes. A sorter provides an interface between the warehouse and order picking to ensure efficient sequencing of the order picking process.

Automatic packing and warehouse management with SAP EWM and MFS ensure further smooth processing. A subsequent value-added service area serves bespoke client requirements and distribution channels.

Consistent use of io’s project portal across all project phases ensured that information was effectively exchanged and integrated. All elements were implemented on time and on budget, allowing the project to be completed in 2015.

All the project objectives – quick availability following stock receipt, shorter throughput times and improved service levels – were achieved with innovative tools and methods.

The first shipments left the new distribution center in 2014.

Key Facts


The Hugo Boss fashion group was founded by Hugo Ferdinand Boss in 1924 and is now one of the world’s leading brands in the premium and luxury clothing sector. From business attire to casual leisure looks, the HUGO and BOSS brands each offer clothes fit for every occasion. The company has a global network with its products available in shops-in-shops and outlets, for example, in 127 countries.

The challenge

  • Increasing demand in e-commerce
  • Complex logistics issues


  • Centralization of several warehouse locations
  • Highly automated processes to minimize logistics costs
  • Automatic small parts warehouse with shuttle system for storage (approx. 400,000 boxes) and picking (approx. 7,500 items/hr)
  • Warehouse management with SAP EWM and MFS
The new shuttle warehouse from Hugo Boss

Shuttle warehouse with a capacity of 400,000 boxes.