Automation In The Crocs Production Line

Crocs, one of the biggest non-athletic footwear brands, has always adapted and improved new technology in its manufacturing process. One key factor that helps them regulate the operation smoothly & efficiently is the automation in the Crocs production line. This article will help you understand why this strategy and how game-changers it means to Crocs.

Backstory: Reason Crocs adapts the automation in the production process

When the pandemic struck in 2020, the Crocs brand hit a skyrocketing record of orders through their e-commerce platform (They increased throughput by 182% during Q4 2020). Therefore, the Crocs team will need to rebuild & upscale its production line to match the high demand faster and ensure quality. A quick analysis shows they will need at least 400 new candidates to support the production & logistics process. Which also requires time and tons of money to hire and train them.

In addition, the company has come up with a brilliant solution instead. With the help of the robotics hand in both the manufacturing & logistic chain, Crocs spectacularly transformed its whole production apparatus with various positive outcomes.

Reality: How Crocs Run Automation Technology  

Crocs has transformed its traditional manual, labor-intensive production into a highly automated system by leveraging cutting-edge technologies for manufacturing processes, such as robotic arms, conveyor belts, and computer-aided design (CAD). Moreover, faster merchandise distribution can be achieved by integrating mobile robots called Chuck’s work at the warehouse.

Automation in Crocs Manufacturing Chain

One of the most significant advantages is the substantial increase in productivity. Robotic arms, for instance, can work tirelessly around the clock, performing repetitive tasks with precision and speed. This has enabled Crocs to meet the ever-growing product demand while maintaining consistent output. Additionally, automation in Crocs’ production has led to significant cost reductions. By minimizing human error and optimizing resource allocation, Crocs has lowered production costs and passed savings on to consumers.

Furthermore, automation in Crocs production has played a crucial role in improving product quality. Automated systems can maintain strict quality control standards, ensuring that each pair of Crocs meets the highest standards of craftsmanship. This has resulted in a more consistent and reliable product, further solidifying Crocs’ reputation for quality and durability.

Finally, the automation chain enhanced workplace safety. By eliminating hazardous tasks and minimizing the risk of accidents, it has created a safer working environment for employees. This has improved employee morale and reduced the overall cost of workplace injuries.

Automation in Crocs Logistic Chain

Another wonderful application of automation in their system is how Crocs uses mobile robots for their pop-up warehouse. They chose 6 River Systems’ configurable and autonomous robotic platform, which uses AMRs called “Chucks,” and applied it to Crocs’ picking process. The AMRs are integrated into the company’s warehouse management system (WMS), and they don’t require any new infrastructure or the need to change your warehouse layout. As a result, they save 50% of the time for associates and eliminate the need to push or pull heavy carts. This system also doubles productivity when compared to manual processes. Specifically, the pick rates at the Dayton facility of Crocs improved from 55 to 111 units per hour after implementing the AMR system. Similarly, new-hire onboarding also improved: Training time went from an average of one week down to one day, according to Fauerbach.

Challenge and Future Vision

Conclusion Crocs had fallen out of favor with consumers in the past. Still, they reemerged as a top shoe brand among Millennials & Generation Z. Crocs surely grabbed on to their opportunities and improved their business by embracing advanced policy & technology. Automation is the best solution for Crocs, providing tremendous improvements with consistent quality in product, increased order-picking rates…Looking forward, the company Crocs may develop the integration of artificial intelligence and machine learning. These advancements will enable Crocs to optimize its production processes further, reduce waste, and achieve greater sustainability goals. Or maybe Crocs can consider applying 3D printing technology on a larger scale with the help of robots’ automated hands.

Also, Crocs cleverly shapes their young customers’ (GenZ) consumer behavior with many eye-catching collaboration promotions with influencers. Celebrity collections, including Justin Bieber Crocs, Post Malone Crocs, and Bad Bunny Crocs, have all embraced the rubber shoes and the Crocs “Come As You Are” slogan. Predictive Analytics for retail helped Crocs capitalize on mainstream popularity and keep their shoes relevant to consumers.

Conclusion

Automation in Crocs production has emerged as a game-changer, propelling the brand to new heights of efficiency, quality, and sustainability. Consequently, Crocs has improved the overall consumer experience and expedited operations by adopting technology innovations. As the overall footwear industry continues to evolve, it is evident that automation in Crocs production will remain a key driver of innovation and success.