A major company in the tooling distribution sector, experiencing significant operational growth, recognized the need for consulting support from aBCD Consulting.
The challenge
To support the need for managing a broader assortment and a growing volume of orders from its partners, the company required a new logistics and operational model.
The new model had to ensure:
High-quality standards.
Optimized operational processes.
Reduced costs.
Scalability.
The solution
After conducting an initial analysis to identify the strengths and weaknesses of the current organization, defining the scope of references and volumes for designing the solution, and establishing a new order fulfillment approach, the aBCD Consulting team carried out:
1. Functional design of the new warehouse
Identification and sizing of automated storage equipment
(vertical lift modules) to manage and optimize warehouse flows.
Identification and sizing of traditional storage equipment.
Determination of space allocation based on an optimized layout
using ABC analysis.
Sizing of the operational team
and handling equipment required to manage the new configuration.
2. Simulation of the designed solution in a real warehouse
Identification of a suitable property
aligned with the design requirements.
Simulation of the proposed project in a real-case scenario, including:
- Removal of the mezzanine structure from the AS-IS situation, replacing it with traditional shelving and vertical order pickers with onboard operators.
- Implementation of modern vertical automated storage systems (MAUT) to optimize storage capacity and speed up picking.
- Maximization of synergies between traditional shelving picking and the automated system.
3. Implementation and operational support
Planning the transfer and reallocation of items
based on the new logistics structure.
On-site support
for the relocation and startup of the new configuration.
Staff training
on the use of new technologies and operational procedures.
Continuous follow-up
to ensure proper functionality and performance measurement.
Results
Thanks to aBCD Consulting’s intervention, the company successfully managed twice the number of SKUs and handled ten times more orders than before, while also achieving:
Ensuring operational continuity
during the transition period.
Improving service quality
by reducing delivery times and picking errors.
Optimizing warehouse space
cutting the average space occupied per item by more than 20% through layout reorganization and the implementation of more efficient storage systems.
Reducing the average cost per order line by 41%
compared to the initial situation.
with the goal of reducing costs and improving service for their customers.
