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Transform a logistics warehouse.

A company transformed its logistics warehouse to increase capacity while maintaining the same headcount, reduce errors, and strengthen its culture of Operational Excellence.

Background

A rapidly growing company needed to adapt its organizational structure to meet rising customer demand, as the current setup was limiting the logistics department’s ability to support the production line in terms of quantity, lead times, and consistency.

It would have been a sure thing if:

  • More than 50% of the volume could be processed with the same number of employees.
  • Manual entries were cut in half.
  • Preparation errors were decreasing, and production stoppages due to a lack of materials were eliminated.

The process:

  • Mapping of the current situation and analysis of the issues encountered.
  • Collection of the data needed to design the logistics solution.
  • Design of the “component supermarket” and the new operating model.
  • Modification of the existing system to support the solution’s deployment.

At the same time : Green Belt training for the Project Manager, and training on the 5 pillars of Lean Management for front-line managers and the Executive Committee to ensure the project’s stability once the consultant leaves.

Our results:

  • Teams that understand one another and recognize each other’s needs.
  • Streamlined communication systems and a single platform that centralizes information.
  • Simplified data collection systems and a significantly reduced number of data entries required.
  • The implementation of the project also provided an opportunity to review the core procedures of related departments and formalize them in line with the Operational Excellence culture.