Project Description
A multi-phase project required relocating and rightsizing the entire operation 20 miles away. Current operations and facility layout were disjointed, inefficient and customer service levels were not being met. The client required lean process improvement, material flow, Warehouse Management System software configuration alignment, Best in Class warehouse layout and material handling equipment.
Client Objectives
Right-size and develop optimized future state layout.
Formulate efficient transfer plan without disruption of sales or productivity.
Create Plan For Every Part tool to enable part management across functional areas and processes.
Introduce Best in Class picking methodology including Vehicle Lift Module batch grouping and order picking.
Process and material flow improvements in kitting, packing and warehousing.
Optimize capacity and improve storage methodology.
Project Outcomes
$1.58 Million labor savings
35% reduction in warehouse footprint
11,000 parts transferred on time with no disruption to customer service levels
30% increase in pick productivity
52% reduction in overall facility footprint (from 435,000 ft. ² to 210,000 ft. ²) while adhering to complex business requirements
100% client implementation of recommendations on layout, material flow, material handling equipment and storage mediums (VLM, rack configuration)