A major international company engaged in the design and production of industrial machinery chose to rely on aBCD Consulting for an in-depth assessment of its factory logistics, with the goal of increasing efficiency and ensuring smoother flows to support production.
The challenge
The company was managing an internal warehouse characterized by:
Slowed goods transit processes
impacting assembly and production capacity.
Uncertainty regarding the proportionality between available space,
volumes handled, and personnel employed.
The need to understand whether the available space was being used effectively
and whether efficiency could be regained through more modern storage and handling solutions.
The main objectives of the project were to:
Improve the speed and effectiveness of warehouse processes.
Obtain a clear picture of existing flows and constraints.
Define optimization strategies and potential expansions.
Evaluate opportunities to further digitalize and integrate organizational processes
particularly purchasing and warehouse operations.
The solution
aBCD Consulting conducted a structured logistics assessment across several phases.
1. Analysis of warehouse processes and flows
Unloading, receiving, stocking and pre-production buffering, goods dispatch.
Mapping of routes and productivity levels.
Identification of inefficiencies and low value-added activities.
2. Analysis of data and production orders
Structure of production orders and types of assemblies handled.
Physical analysis of assemblies and stocked materials.
KPI collection and definition of internal benchmarks.
3. Layout analysis and storage opportunities
Assessment of the current arrangement of goods
Development of an optimized layout
with quantification of recoverable space through vertical storage solutions.
Identification of suitable equipment
(racking, automated storage systems, vertical order pickers, tote-handling carts).
4. Evaluation of organizational processes
Review of the reorder process and order monitoring.
Analysis of digitalization opportunities and synchronization of flows
between purchasing and logistics.
Identification of organizational issues and opportunities
5. Implementation of the improvement plan
Gradual execution of operational and organizational proposals
to optimize processes.
Implementation of technical solutions
with productivity and scalability projections.
Results achieved
Thanks to the intervention of aBCD Consulting, the company was able to:
Recover more than 3,000 pallet positions
with scalable expansion potential up to the ideal warehouse size.
Increase productivity by 50%
thanks to the reduction of low value-added activities and the elimination of search times and multiple handling.
Normalize flows to production
ensuring that only necessary materials reached the assembly area, freeing up space and increasing production capacity.
Improve service quality
toward internal functions (particularly production) and end customers.
Increase goods traceability
through a more structured and digital management of flows.
Define a clear investment plan and logistics solutions
(optimized layout, new equipment, digitalization) capable of ensuring efficiency and future scalability.
visit our page on Warehouse Logistics Costs.
