The ups and downs of Comline Group’s Bedford move

Comline Group’s significant investment into its new global headquarters at Bedford Commercial Park, aims to enhance efficiency, strengthen company culture, and reaffirm its commitment to loyal customers. Here’s the second half of PMF Editor Tom Henman’s two-part exclusive.

Introducing AutoStore™: a technological leap forward

One of the most significant advancements in Comline Group’s new Bedford facility is the implementation of AutoStore™, which is an automated storage and retrieval system that utilises a fleet of robots for rapid and efficient picking.

The innovative technology allows inventory to be stored in plastic totes stacked up to 16 deep, with 60,000 totes currently in the Comline Group system. Thirty-six robots move along a grid, pick the plastic tote containing the required component, and deliver it to ports where warehouse operators complete the pick and prepare the product for dispatch.

Comline Group Managing Director, Ishan Kamdar (right), outlined the key benefits of this system: “First, because the stock isn’t stored in traditional racks and aisles, there’s no wasted space between boxes. AutoStore™ reduces space requirements by as much as 70%, making the stocking and picking process significantly more efficient.

“Second, the robots handle all the stock retrieval, drastically reducing the average pick time. This is a key metric in our operations. The new system has cut pick times from several minutes, as operators previously moved from one end of the warehouse to the other, to just seconds. This increased productivity reduces physical strain on the staff, leads to fewer mistakes, and higher accuracy in order picking.”

Furthermore, the robots are self-sufficient; they charge themselves when their battery levels drop below 40%. The system has the capability to run continuously; in fact, during the transition to the new site and the AutoStore™ implementation, Comline Group operated 24 hours-a-day to minimise customer disruption. The operation now has a brief shutdown from 1am to 6am, but the option is there for Comline Group to move back to a 24-hour operation at any time.

Watching the robots in action was mesmerising – they move with speed and precision, seemingly on the brink of collision but always stopping just in time! Ishan explained the system’s sophisticated traffic management prevents collisions by coordinating all movements on the grid.

Despite the impressive speed, the robots also boast incredible accuracy.

“People still add the critical layer to our operations”

While the AutoStore™ system is a technological marvel, Comline Group remains “committed to retaining the human element” in its operations. Ishan emphasised that, despite the automation, the role of skilled operators is crucial. These operators work in collaboration with the AutoStore™ system, to ensure smooth operations and handle complex tasks that require human judgment, adaptability, and intervention.

Ishan continued: “Automation has certainly streamlined our processes, but it’s our people who add the critical layer of oversight and quality control. Their expertise is irreplaceable, especially when it comes to handling unexpected issues or larger orders to meet specific customer needs.

“The technology is designed to work in harmony with our people, working to increase speed, capacity and efficiency. Our operators are the crux of our operation and integral to achieving our customer service ambitions.”

Acknowledging the challenges

Undoubtedly, Comline Group’s move to Bedford Commercial Park is a significant milestone, but it has not been without its challenges. Relocating more than 8,000 pallets, over 25,000 part numbers, and hundreds of thousands of SKUs was an immense logistical task, not to mention the introduction of AutoStore™, which is requiring the organisation to adapt to new processes and ways of working.

Ishan was quick to acknowledge the patience of the company’s customers: “We understand that this move has caused disruption for our loyal customers, and I would like to take this opportunity to publicly thank everyone for their patience.

“I cannot overstate the scale and complexity of the move, and with a project of this magnitude, some level of disruption was inevitable.

“What I can guarantee our customers though, is that their patience will be rewarded. This move, and the investment in AutoStore™, will revolutionise our business and elevate our service offering to new levels.”

Strengthening customer focus

Beyond the technological upgrades, the move to Bedford Commercial Park is fundamentally about strengthening Comline Group’s relationship with its customers. Emphasising this point, Group General Manager – Marketing and Communications, Leigh Davies commented: “While it’s great to have new facilities and advanced systems, the primary goal is to enhance our service offerings.”

Comline Group’s previous location in Luton had its limitations, which the new site overcomes with greater stockholding capacity and faster order processing. Although the move has presented challenges, much like moving into a new home, the excitement about the potential of the new site and the opportunities it presents is evident. The company is committed to ensuring that the move translates into tangible benefits for its customers.

A proud moment for the Kamdar family

Visibly, the relocation to Bedford Commercial Park represents a significant investment by Comline Group and, undoubtedly, it is a proud moment for the Kamdar family.

Spearheaded by its founder and chairman, Divyesh Kamdar, the family has guided Comline Group from its humble beginnings in a small office in Wembley in 1991 to its new state-of-the-art facility. Divyesh continues to play an active role in the business, whilst his eldest son, Ishan, as managing director, is now in charge of the day-to-day operations, and youngest son, Shalin, occupies the position of financial director.

During my visit, I was struck by the presence of three generations of the Kamdar family: Divyesh, Ishan and Shalin were all on site, while Ishan’s wife and young son had even dropped in for a first glance at the AutoStore™ robots! This move is a testament to their continued commitment to the business, and there is rightly a clear sense of pride in what is the biggest step in Comline Group history.

The final word…

Comline Group’s move to Bedford Commercial Park marks a new era for the company. It is characterised by modern technology, a revitalised work environment, and a staunch commitment to customer service. The transition, while not without its challenges, positions the company for continued growth and future success. As the organisation’s dedicated team looks ahead, the foundations they have laid ensures that Comline Group is wellequipped to meet the evolving needs of its customers in the UK and around the world.