Warehouse Efficiency Improvement

A leading industrial glove manufacturer was struggling with 60% on-time shipments across the different channels. The warehouse capacity was constrained for different process areas and overtimes were continuing to increase. Scalability to support growth did not exist. The P2E team was tasked with transforming the warehouse operations to support scalability, improve service levels, increase productivity and to leverage the existing facility through a layout redesign

Benefits identified include

  • 15 – 25% improvement in receipt thru putaway
  • 50 – 60% improvement in returns operations
  • 35 – 50% improvement in pick, pack and ship process through batch/wave/zone/cluster picking
  • 60 – 70% reduction in cycle count labor
  • Slotting and layout redesign extended the capacity by an additional 20%

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