American Eagle Outfitters is a global apparel and accessories brand serving retail and e-commerce customers worldwide. AEO aimed to streamline fulfillment across both channels using a unified fulfillment system. The result was faster delivery, greater efficiency, and a scalable framework to support continuous growth.
One inventory pool serving retail and e-commerce
Service level agreement
Unit sorter utilization
Retailer capacity per unit
E-commerce capacity per unit
AEO needed to serve its fast-moving, digitally savvy customers with speed and precision across both e-commerce and retail channels. As online order volumes increased, the retailer’s legacy fulfillment systems struggled to keep pace.
square foot distribution center
units of active inventory
SKUs managed
order processing time
15–35 year-old digital shoppers expect “buy now, ship now.” AEO needed to make fulfillment as fast and seamless as the shopping experience itself.
VARGO® designed AEO’s omnichannel fulfillment center in Hazle Township, Pennsylvania, powered by COFE®, a real-time Warehouse Execution System that enables continuous processing. Unlike batch “wave” systems that release orders in large intervals, COFE® evaluates every incoming order as it arrives.
Every incoming order is prioritized by customer need, shipping priority, and inventory position.
High-priority orders move to the front of the queue for faster turnaround.
Every SKU can fulfill both retail and online orders from one pool.
COFE® orchestrates labor, routing, and allocation without increasing headcount.
Through COFE®, automation technologies were integrated and synchronized to deliver a unified, seamless fulfillment process from receiving through shipping.
Knapp shuttleDematic RapidStore AS/RSOPEX® Sure Sort® automated putwallsBeumer cross-belt sorterManhattan WMS
Even during major peak seasons, the new facility processed as many orders in six days as it once did in three months, all while maintaining service-level accuracy and customer satisfaction.
Today, AEO continues to scale by integrating robotics and automated storage systems under COFE®, increasing capacity without expanding labor or footprint.
Schedule an operational assessment, explore a COFE® demo, or visit a reference site.
