

DISCOVER OUR RANGE OF PROJECTS

NEW MULTIPURPOSE LOGISTICS CENTER & NEW IT SOLUTIONS
Major Fruits & Vegetable distribution company requested our assistance in designing new multipurpose logistics center. The company has active portfolio of more than 700 varieties of fruits, berries and vegetables that are imported from 50+ countries. The new facility has 4 different temperature-controlled zones, isolated temperature & humidity-controlled storage chambers, ripening chambers, sorting / grading automation, dedicated packaging production area, company's office space, logistics control tower, logistics yard for own-fleet and car parking.
Footprint 19.500 m2 | 23 docks | Grading automation for Fruits & Berries | Cartoning machines | Conveyors | Ripening chambers
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360° Logistics assessment
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Implement Quick-Wins and layout changes in existing warehouse
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Develop warehouse operations sizing model (7 years window frame)
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Design operational layout and office layout for new distribution facility
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Design layouts for the office and logistics control tower
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Define needs and requirements for automation, equipment and personnel
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Select technology and equipment, conduct tendering procedure (manufacturing equipment, conveyors, sorters, forklifts...)
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Develop IT landscape, change management for ERP, implement new WMS and MES.

BEST OF BREED LOGISTICS AUTOMATION JOURNEY
We proudly supported our key DIY retail client in his 5 year logistics automation journey. The project started with definition of clear supply chain strategy with focus on cross-docking activity. To enable execution of the plan we started with WMS implementation which after the roll-out powered all operations of central and regional distribution centers. State of the art fully automated solution was launched on the later stage. Our team defined specific approach to maintain 24/7 support of applications. As the result, we developed very strong partnership with transparency and high efficiency.
State of the art hybrid automation | One WMS solution | ASRS | ATLS | AGVs | Gravity racks | Conventional racks | Cross-docking
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360° Logistics assessment and supply chain strategy definition
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Selection of IT solutions: WMS, TMS
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Configure core-mode solution. The first central warehouse was launched within first 6 months
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Adjust core-model for 3PL deployment. WMS as the SaaS application of the retailer
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Dedicated team to provide quick customer response and manage new requirements
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Definition of dark store core model to de deployed into 50 locations
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Integration of the solution support team in the ticketing system of the retailer
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Deployment of the core model to all federal and regional warehouses
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Implement new core model to support ADAPTO solution of Vanderlande which is designed for rapid response time
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Connect AGVs and other automated solutions

OPERATIONS RE-MODELING FOR KEY PHARMA DISTRIBUTOR
Major retailer acquired higly-automated distribution center to expand business activities and introduce new store formats. Our customer was concerned with warehouse throughput. After 3 days on site we proposed transformation plan and for the next 4 months we were in charge of daily operations. We changed layout, implemented new org structure and KPIs, adjusted stock allocation rules, supplied new equipment, trained staff. We delivered the project during COVID restrictions and it was mandatory to implement transformation without stopping vaccine shipments.
Footprint 76.000 m2 | 7 zones | 25 docks | 16.000 storage locations | 14.000 picking locations | 400+ people | 2 shifts
KNAPP OSR & SDA, PCA Roboter, Rotomats, conveyors for picking, packing and sorting, gravity racks, conventional racks, VNA racks...
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360° Logistics assessment, proposition of transformation plan
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Warehouse assortment optimization, implement put-away and picking according to ABC principle,
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Implement MIN-MAX stock management and picking location replenishment
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Change layouts without stopping operations (existing racks repositioned, new MHE supplied)
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Increase density and cube-utilization efficiency
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Train staff to work with automation equipment, including preparation training materials, instructions and SOPs
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Implement new organizational structure, KPI tracking and reporting system
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Implement operations planning using activity based costing principle

IMPLEMENT WAREHOUSE KPIS & INCENTIVE PROGRAM
Our client approached us to make an in-depth study of existing calculation algorithms for key logistics KPI's. As the project's outcome we delivered new reporting dashboard for the management of the company with alert functionality. We reviewed data collection and processing techniques. The dashboard supported view of the statuses of all distribution centers with drill-down capability and zoom-in to specific logistics process. All the KPI calculations were aligned to meet industry standards and allowed for the benchmarking implementation. The project helped management to adjust supply chain operations.
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Review logistics KPIs and calculation formulas
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Review data collection and transformation flows
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Describe approach of logistics KPI calculation
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Implement standardized KPI calculations
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Create management KPI dashboards
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Provide documentation and training materials
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Implement new incentive program for warehouse employees

GLOBAL LOGISTICS AUDIT FOR LEADING FOOD RETAILER
Major retailer with 45 distribution centers serving 28.707 stores requested our help to identify improvement possibilities. The scope of our project was limited to 5 key distribution centers and 4 stores that spread across the country. Our goal was to identify areas of possible change specific to each individual logistics object and to create general supply chain transformation road-map. During the investigation we touch such aspects as internal warehouse logistics processes, layouts, stock allocation rules, KPI's and incentive program, WMS functionality, HQ processes of sourcing, purchasing and replenishment.
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360° Logistics assessment for 5 distribution centers and 4 stores spread across large county in 4 weeks
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On-site picking, put-away, replenishment and stock control games to compare reporting data and real GEMBA picture
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ABC and warehouse heat-map analyses
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Review condition of key warehouse equipment and maintenance plans
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Proposition of transformation plans for each DC / store including layout and process changes
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Proposition of changes for warehouse incentive program
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Review of WMS, YMS and TMS functionalities, change recommendations
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Review and recommendations for HQ processes of sourcing, purchasing, stock allocation and store replenishment
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Review automatic ordering procedures, replenishment frequency and functionalities of related IT systems.
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HQ workshops to adjust purchasing / allocation strategy
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Proposition of general supply chain transformation road-map

LOGISTICS MASTER PLAN FOR LEADING BEVERAGE COMPANY
UK based company contacted us to make a study of logistics flows and layouts of finished goods warehouses located on several production sites. During the study we proposed quick-win solutions and long-term plan to move from bulk storage to automation. We created several tools to maintain optimal stock allocation aiming to optimize total logistics cost (storage, handling and transportation). Our data-driven digital-twin model of logistics flows was used multiple time to create simulations of operational costs and support solid business cases that helped to kick-off warehouse automation projects.
2.000+ SKUs | 2 production sites | 10+ own warehouses | 4 external warehouses | International shipments
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Study of network and logistics flow for 2 production sites
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Proposition of layout changes for finished goods warehouses
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Data-driven digital-twin model of logistics flows
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Capacity requirement calculations (storage space, unloading / loading bays and docks)
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Warehouse automation projects (high-bay ASRS, conveyors, ATLS...)
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Automation throughput simulation
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Change request for WMS and ERP: high-bay conveyor routing model, warehouse heat-map stock views, stock allocation policy

WMS IMPLEMENTATION FOR 20 FEDERAL AND REGIONAL DCs
Leading diary product manufacturer selected our team to lead digital transformation of logistics operations that covered whole distribution chain of the country. During the project we implemented WMS for 8 production sites, several distribution centers and connected key 3PL operator. Our approach was based on pre-configured core-model WMS functionalities that were adjusted to meet specifics of each site. Deep understanding of our client's business and dedicated team ensured smooth start of operations within short timeframes. By the end of the project we connected near 20 distribution centers.
20 WMS implementations within 1 year | Factory warehouses | Distribution HUBs | Distribution centers of dedicated 3PL operator
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Prepare business case for the IT implementation program
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Define and configure WMS core-models for factory warehouse, distribution hub, 3PL operator
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Design IT architecture and validate data flows between ERP / WMS / TMS / Quality management system (Guardian)
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Implement pilot WMS project and adjust configurations
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Validate savings model based on real data captured after go-live (improved efficiency, reduced losses, service level +4%)
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Define deployment strategy to secure on-time roll-outs without drops in operations levels
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Roll-out of 20 sites through regular waves with dedicated team within 1 year timeframe
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Adjust approach for implementation during COVID travel restriction

EXTENSION OF FINISHED GOODS WAREHOUSE
This project is the second phase of factory master plan that we created earlier for a major diary product manufacturer. Our task was to check the solution according to the new volume initiatives. We put new parameters in the warehouse sizing model and adjusted number of required storage & picking locations, shipping docks, FTEs and material handling equipment. Additionally, we designed special temperature controlled ASRS buffer and conveyor that transports items from production lines to finished goods warehouse. New warehouse section was constructed and layout changed as per plan.
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Quick on-site audit
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Updated warehouse sizing model
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ASRS and transport conveyor
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Finished goods warehouse extension
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New layout, rack repositioning
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Changes in WMS system (new locations, put-away strategy, replenishment rules, picking methods, routing)

MASTER PLAN FOR BEVERAGE DISTRIBUTION CENTER
Distribution company that provides beverages, glasses, bar equipment and furniture for big events and local bars contacted us to optimize logistics network and improve warehouse operations. There were 2 facilities in the scope of our study. There was no WMS and all the transactions were logged in ERP. Within 6 weeks we developed master plans for each facility and delivered layout proposals. After that we focused on WMS selection process and proposed several options. The final outcome of the project was a 3 year transformation plan synchronized with investment plan.
Footprint 10.000 m2 | Assortment of 1.500+ SKUs | 8 bays | Mezzanine constructions | Mobile & Conventional racks
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Logistics network quick-scan
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Master plans for 2 warehouse facilities: layouts, list of required equipment and it's quantity
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WMS selection project

LOGISTICS NETWORK REVIEW AND LAYOUT STUDIES
Global beverage manufacturer requested supply chain assessment of recently integrated business in the region of Canary Islands. Our task was to review distribution model, capacity management and warehouse logistics. We inspected 2 production facilities and multiple distribution centers, identified list of quick-win opportunities, built digital-twin model of product flows, completed network model simulations with assessment of logistics costs, increased capacity by changing warehouse layouts, and developed transformation plan to align operations according to the company standards.
Footprint 17.000 m2 | Assortment 800+ SKUs| 6 islands | 2 production sites | 15 warehouses
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Logistics network review, flow modeling and cost scenario simulations
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Implementation of Quick-win initiatives
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Change layouts of warehouses to increase capacity
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Transformation plan of logistics operations

BREWERY LOGISTICS MASTER PLAN
Major beverage manufacturer asked our team to review logistics of one of the oldest and largest production facilities in Belgium. The goal of our mission was to find the way of capacity improvement, identify possibilities of product flows optimization, improve safety aspect of operations and increase number of shipments. The site used a combination of transportation modes to bring products to customers: railroads, ships and trucks. High-bay. We developed short-term and mid-term initiatives that were easy to implement. Among the long-term initiatives we proposed ASRS solution and ALTS systems.
Footprint 35.000 m2 | High-bay warehouse | Gravity racks | Pallet conveyors | Automatic truck loading system | Bulk storage
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Quick scan audit of logistics operations
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Develop layouts for several on-site warehouses to increase capacity
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Automation concept: ASRS, pallet conveyors, ATLS

FINISHED GOODS WAREHOUSE
Our customer sent us to investigate the opportunity of warehouse core-model application for one of the production sites undergoing reconstruction. On that stage it was still possible to change the final solution, so we adjusted building structure dimensions and proposed modified warehouse layout. Within 2 weeks our proposition was put into realization by local architects. In the meanwhile we prepared the list of necessary warehouse equipment and contacted suppliers.
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Quick scan of the facility and operations
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Adjust warehouse concept and layout
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Arrange warehouse equipment delivery

WAREHOUSE LAYOUT STUDY FOR BEVERAGE FACTORY
Major beverage manufacturer requested to study possibilities of on-site capacity improvement, logistics cost reduction and process optimization. The factory has previously undergone through several phases of extension and as the result consisted of multiple interconnected buildings with varying height. Finished goods were transported via railroad and by trucks. We developed solution that increased capacity by 28% and was feasible investment wise. To support the solution we created additional simulation models with focus on stock allocation and movement simulation.
Footprint 22.000 m2 | 6 interconnected warehouses | 400 SKUs | 20+ docks | 2 railroad platforms
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Quick scan of logistics operations
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Volume improvement simulation
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Sizing models for finished goods warehouse, packaging materials, ingredients and raw materials
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Concept of site logistics and flows
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Detailed layout design for on-site 6 warehouse
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Develop SKU allocation strategy and simulation put-away and picking paths
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Warehouse equipment requirement calculation and supplier/model selection
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Support implementation

EGG PROCESSING PLANT AND DISTRIBUTION CENTER
Poultry company contacted us to support the project of vertical integration. The key business activities were focused on egg production of 2 private-label brands and egg packaging for major retailers. We started with global audit of the supply chain, including: feeding production, breeding, slaughterhouses, egg-processing facilities, and logistics. Then we simulated various scenarios of vertical integration. One of the initiatives implied construction of egg-processing plant and new distribution center. We prepared sizing model, assisted with site-location selection and developed facility layout plans.
Footprint 18.000 m2 | 120 FTE | Production of over 6.000.000 eggs / day | Poultry farms in 3 regions | Countrywide distribution
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360° Supply chain assessment: feeding production, breeding, slaughterhouses, egg-processing facilities, and logistics
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Implementation of lean logistics principles for farms, production sites and warehouses
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Scenario simulation of vertical integration and revenue / cost modeling
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Develop concept of future supply chain with focus on production capabilities and own distribution center
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Selection of equipment for process automation
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Detailed design of production site and distribution center
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Definition of future IT-landscape
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Support implementation

MAIN DISTRIBUTION CENTER FOR FOOD RETAILER
Luxembourg-based retailer with 200+ stores that offers a range of food and non-food products requested us to make a study aiming to centralize logistics operations. The company had several medium-size warehouses and developed three formats: hypermarkets, discounters, and e-commerce. We modeled level of centralization per each product category using Point-Of-Sale data of each store, adjusted results with store opening plans and calculated gravity center taking into account lead-time simulations. Then used calculations to make warehouse sizing model and produce layouts.
Footprint 66.000 m2 | 6 block | 3 temperature zones | 80 docks | 61.000 storage locations | 36.000 picking locations | 65.000 SKUs
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Modeling scenarios to determine optimal logistics network configuration
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Sizing model for distribution center
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Layouts for 2 distribution centers (1 central, 1 regional)
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Identification of key equipment supplier
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Support go-live activities
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Support implementation of AGVs
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Support WMS selection and implementation

DENSE AUTOMATED STORAGE FOR BEVERAGE MANUFACTURER
Major beverage manufacturer requested our assistance to come up with business case that would maximize on-site storage capacity and reduce associated logistics costs. We started with examination of on site capacities and building possibilities. Then we created digital flow/cost model and simulated various scenarios. The best option was to invest in high-density automated warehouse. Our solution consisted of pallet conveyor, powered shuttle racks, gravity racks, several mezzanine structures and conventional racking. The warehouse is a unique combination of case picking activity and full pallet shipping.
Footprint 6.000 m2 | Free height 9.5 m | Capacity 12.000 pallets | 700+ SKUs | 14 docks | Conveyor throughput 1.200 pallets / hour
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360° Logistics assessment: on-site flows, usage of external warehouse, benchmarking of warehouse operations
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Flow model and logistics cost simulation
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Business case with evaluation of various solution: new warehouse vs. layout changes vs. high-density automation
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4 warehouse layouts: finished goods, dry goods, packaging materials
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Key supplier identification, equipment model selection and comparison
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Supervising reconstruction and equipment installation
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Implementing KANBAN based put-away / picking for transition period (no WMS)
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Supporting WMS implementation

DEDICATED CUSTOMER LAYOUT FOR 3PL COMPANY
Europe‘s leader in beautiful living e-Commerce contacted us to design warehouse layout that will suite it's operations on a new market. It was decided that operations would be executed by 3pl company in the dedicated warehouse. We worked together to define target categories, storage capacity and desired throughput. The layout arrangement was focused on serving 4 flows: pieces, cartons, pallets, bulky / oversized items. Conveyor system transported items from packing stations to shipping consolidation zone.
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Quick scan of pre-selected warehouse facility
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Warehouse sizing model and layout
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Selection of equipment suppliers

MODERN FASHION LOGISTICS CENTER
Fashion retailer selling premium brands and it's top quality private label products in more than 100 stores expressed a desire to consolidate logistics activities. Our mission was to develop the concept of modern distribution center, including: location of the facility, it's dimensions, type of warehouse equipment per each product category, office space plans, car parking, yard plan, on-site flows. Key aspects of project: the overhead conveyor for transportation and storage of hanging items, temperature / humidity-controlled warehouse sections, multi-level mezzanine, conventional racking for pallets and cartons.
Footprint 10.000 m2 | 85.000 active SKUs | 35.000 hanging locations | 1.000 orders / day | 25.000 lines / day
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Quick-scan of 4 warehouses, supply chain planning, stock allocation and store-replenishment processes
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Warehouse sizing model. Simulation of logistics costs based on the location of new distribution center
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Site master plan, logistics and office layouts
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Select key equipment suppliers
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Support WMS selection and go-live activities

CONCEPT OF FINISHED GOODS WAREHOUSES
Global manufacturer that offers fresh dairy products, bottled water, early life nutrition and medical nutrition products contacted us to develop the concept of finished goods warehouses. In the scope we had 5 production sites. We started with digital-twin of the flows and warehouse sizing. Having in mind the strategic plans and constraints of sites we proposed to use phased out approach. It was focused on warehouse layout adjustments, not on warehouse extensions. We defined core-models for warehouse structure, office spaces, warehouse equipment, layouts. On the later stages we were supervising roll-outs.
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Audit of 5 production sites and logistics operations
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Cataloging blue-prints, drawing, building permission etc.
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Product flow digital-twin and warehouse sizing models
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Core-model of warehouse structure: column grid, operating heights, building materials, insulation specs, key suppliers.
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Core-model of logistics control tower and office spaces: layouts build around lean human flows
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Core-model of layouts and racking solution per each phase: detailed blue-prints of modular solutions, retrofitting plans.
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Core-model of warehouse equipment: major suppliers and models for racking, material handling equipment, docks, doors...
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Adaptation of the core-model. Detailed drawings and specifications for each of 5 production sites.
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Supervision of projects for each production site.

SUPPLY CHAIN EVOLUTION & NEW DISTRIBUTION CENTER
Family-controlled men's fashion retailer with 120+ stores requested us to complete an independent audit of the supply chain. Their core business is to design, produce and sell men's suites, coats, shirts, ties, underwear, shoes etc. Supply chain of the company consists of multiple factories and several consolidation centers around the globe. During this 2-year journey we helped our customer to evolve by introducing and implementing new IT solutions, designing new distribution center and moving operations there, steadily introducing new processes in the whole supply chain from sourcing to store operations.
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Global supply chain audit (collection planning, sourcing materials, manufacturing & purchasing, warehouse and store operations...)
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Design of target IT landscape
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Warehouse layout planning
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Move operations to new distribution center / office building
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IT implementation projects: ERP, WMS + RF, POS integration
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Implement new logistics processes: cross-docking, pick-by-line, picking wave management, SSCC receiving in stores...

FASHION RETAILER WAREHOUSE
Fashion retailer decided to restructure business. Transformation plan consisted of several initiatives: reduce number of own stores, change supply chain model, increase number of franchisee stores. Our consultants helped to implement multiple aspects of this transformation plan including the design of new warehouse which key activity became processing of pre-allocated cross-docking. New push-oriented distribution model implied maximizing stock in stores and keeping minimal stock in the warehouse. During the project we changed IT systems to implement proper labeling on supplier side.
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Change warehouse processes
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Design layouts of the new warehouse and office spaces
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Move operations to the new warehouse
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Change IT systems to support pre-allocated cross-docking
