Warehouse, Fulfilment & Process Improvement

Map inbound, storage, picking, packing, outbound and returns using data, floor observation and lead times.

• Analyse volumes, processing time, backlog, errors, productivity and space utilisation
• Observe the physical flow and measure waiting, movement and rework
• Identify the binding constraint across process, layout, systems, staffing and planning

Translate forecast, seasonality and order mix into people, station, space and shift requirements.

• Convert forecasts, seasonality and order mix into required hours and workstations
• Model capacity by process step, shift, day and peak scenario
• Test sensitivity to absence, productivity, growth and physical constraints

Redesign sequences, ownership, standard work and exception handling to reduce movement, waiting and manual work.

• Remove unnecessary steps, handovers, movement and manual decisions
• Define operational sequences, standard work, ownership and exception handling
• Assess layout, slotting, batching, picking, packing and replenishment changes

Define useful throughput, accuracy, backlog, utilisation and cost-per-order KPIs with action-oriented routines.

• Build KPIs for throughput, accuracy, backlog, utilisation and cost per order
• Define target, owner, frequency and data source for each measure
• Introduce daily and weekly routines that convert variance into action

Compare investment, variable cost, control, flexibility and risk before expanding, opening or outsourcing fulfilment.

• Compare capital, fixed and variable cost, control, flexibility and risk
• Include transition, systems, management overhead, peak and exit costs
• Test growth and break even scenarios, not only the quoted 3PL rate

Support readiness, testing, ramp-up and early-week problem solving until target capacity is reached.

• Define the integrated plan, dependencies, testing, training and go live criteria
• Prepare the ramp, pilot volumes, contingency actions and decision ownership
• Run hypercare and root cause resolution until target capacity is achieved