A global retail supplier of major lines to the retail trade including all major national supermarket chains. Based in Nottingham, central England, their turnover was £100 million with 1.3 million units dispatched throughout the UK each week.
The company was going through a major expansion process and was unable to cope with the demand through its 100,000 sq ft warehouse. It had also recently changed its warehouse management system, and was experiencing some severe problems in stock replenishment and pick productivity
Duration
9 months
Brief
The initial brief was to review their replenishment and picking system and submit proposals to the board on how they can improve the operation. The client subsequent extended the contract three times to address these additional issues:
- Plan and implement new stock take systems and procedures with their new software system.
- Investigate and submit proposals to the board to introduce a RF Bar code system within the warehouse operation.
- Submit proposals on how their returns operation could be improved
Achievements
· The client accepted the proposals for the replenishment and picking system and requested their implementation. The picking line layouts were changed to increase storage areas, and replenishment systems were changed resulting in improved product availability. Purchase of new equipment was authorised and I managed their supply and installation.
· Increased picking and packing efficiency by 20%.
· Introduced additional conveyor systems to cope with anticipated demand of 20% year on year.
· Warehouse reorganisation resulted in increased capacity to handle additional turnover forecasted for the next 4 years
· Developed and implemented a new stock take system, and managed the stock take of the 100,000 sq.ft. warehouse with a stock value of £10 million. This was completed in one weekend, without any loss of sales during the working week. Previously, they closed the operation down for 7 days to run the stock take.
· Submitted a proposal to the board for an RF bar code system for the warehouse which would improve stock accuracy. This proposal was accepted and implementation continued after contracted period concluded.
· Submitted proposals on how the client could increase their book distribution and returns business for the next 4 years by operating out of an additional 50,000 sq ft. warehouse. The proposal included site options, warehouse design layouts, staffing levels, complete costings for materials and staff showing an annual cost saving of £250,000. The new warehouse would be able to handle a 100% increase in their book business with all the major UK supermarkets. The client accepted the proposals, but decided to postpone the final decision until later in the financial year.
· Testimonial below
