Optimization of a Regional Distribution Center
An audit of the logistics chain for a major packaging materials producer, aimed at reducing inventory costs and improving order picking accuracy.
The Challenge
The client faced high inventory costs due to inefficient storage layout and an order picking accuracy of only 92%. This led to delays and unnecessary corrective shipments.
Our Approach
We conducted a detailed process audit, analyzing data from the WMS and mapping workflows. Subsequently, we simulated various layout scenarios.
Implementation
Based on the analysis, we implemented an ABC storage layout and introduced a new pick-to-light system for the fastest-moving items.
The Result
Lower inventory costs
Picking accuracy
Faster order processing
Investment payback period
The optimized processes and new layout resulted in significant cost savings and a strong improvement in operational reliability. The staff received training for the new system.