Streamlining Warehouse Operations

You might think you're saving time, but you're actually creating inefficiencies Here's why: You're stuck in a bad habit of batching your work. ___ Batch Production is an old-school manufacturing practice where identical or similar items are grouped together, before moving on. They do this to keep machines running and to avoid lengthy changeovers. But there are many downsides. One of them is overproduction. Operators lose focus working on large batches, while equipment drifts out of standards between changeovers. Operational snags: -Long lead times -Uneven workflow -Inefficient space management -Defects hide among the batches -Piles of WIP inventory waiting for the next step These lead to: -Some stations being overloaded, others waiting -Low responsiveness to customer demand -More scrap and rework -Higher carrying costs -Facility costs up Luckily, there is a way out: Switch to One-Piece Flow (OPL) With OPL, workcells are arranged so that products can flow one at a time. Changeovers become quick and routine. Main benefits: +High customer responsiveness +Minimal work-in-process inventory +Quality issues are detected immediately +Reduced wasted space and material handling +Easy to level load production to match takt time Choosing between batch and one-piece flow can have HUGE impacts on quality, productivity, and lead time in operations.

Because inventory causes exponential pain with multiple warehouses... This infographics shows how to manage inventory in this context: ➡️ Centralize Inventory Visibility ↳ Issue: not knowing inventory levels across locations can lead to overstock in one warehouse and stockouts in another ↳ Action: Implement an inventory management system/ ERP that shows real-time inventory positions for all warehouses in one snapshot ➡️ Classify Products and Prioritize ↳ Why: Not all SKUs deserve the same treatment; some are high-value, others are seasonal ↳ Action: Use ABC analysis to rank products by focusing on A-items for tighter control ➡️ Define Replenishment Rules by Warehouse ↳ Why: Different warehouses cater to different regions or demand patterns. One-size-fits-all reorder points (ROP) won’t cut it ↳ Action: Tailor ROP, safety stock, and min-max levels by location. Consider lead times from central distribution centers or suppliers for each site ➡️ Breakdown Forecast by Warehouse ↳ Why: Each warehouse faces unique market dynamics ↳ Action: Generate warehouse-level forecasts, combining local sales trends with broader S&OP inputs ➡️ Plan Transfers Strategically ↳ Why: Sometimes it’s of lower cost or faster to transfer stock than reordering from suppliers ↳ Action: Set up a transfer framework; regularly review surplus vs. deficit at each location. Automate triggers for transfer orders when it’s cost-effective. ➡️ Monitor KPIs Proactively ↳ Why: Multi-warehouse complexity can hide inefficiencies when not tracking the right metrics ↳ Action: Track fill rate, inventory turnover, stock aging, and transfer costs at each site. ➡️ Plan Direct Dispatches & Save Costs ↳ Why: Dispatch directly from the plant to save logistics costs ↳ Action: Prepare daily dispatch plans targeting direct replenishment from the plant and use these warehouses for milk runs for distributors Any others to add?

Picture a small e-commerce client watching 15% of their monthly revenue vanish due to warehouse errors. 📉 Three months later? Their error rate plummeted to under 1% after implementing strategic automation solutions. Here's what most business owners overlook about warehouse automation: It's not just about the flashy robots. 🤖 After helping dozens of businesses streamline operations through automated systems, I've discovered that successful warehouse automation relies on three critical factors: → Strategic placement of technology where it delivers maximum value → Real-time visibility systems that catch stock discrepancies before they become costly problems → Phased implementation that preserves your existing workflows The biggest mistake I witness? Companies attempting to automate everything simultaneously. Smart automation begins small. Target your highest-impact, lowest-risk processes first. For most operations, that means inventory tracking and order sorting-not those impressive robotic arms everyone discusses. Yes, upfront costs are substantial. But when you factor in reduced labor expenses, improved accuracy, and the ability to scale without proportional staffing increases, the ROI becomes clear within 18-24 months. The key lies in understanding which automation solutions align with your current volume and growth trajectory. A 10,000 square foot operation requires different solutions than a 100,000 square foot state-of-the-art facility. What's your biggest warehouse challenge right now? Let's discuss how automation might help solve it. 💬 #EcommerceSolutions #LogisticsExcellence

These 2 metrics impact your warehouse efficiency the most. Number of touches and the time between tasks. These are fundamental questions I ask when evaluating automation: 𝟭. Will this reduce the number of times product is touched? 𝟮. Will this reduce the amount of time between touches? This helped me recently show a brand how to remove 4 touches and several hours of dwell time from their inbounding process. Which also freed up thousands of square feet in their receiving area previously used for staging. 𝗢𝗿𝗶𝗴𝗶𝗻𝗮𝗹 𝗺𝗲𝘁𝗵𝗼𝗱: Each item was received at the dock then manually sorted by many workers into cages suitable for order picking lifts. When a cart was filled it was moved to a staging area. It took between 30 minutes and an hour for a lift driver to retrieve the cart then drive down the aisle to put away locations. When the pick shelving needed replenishment another order picker would drive down the same aisle , retrieve master cartons, then take them to the carton flow area. Another worker would then remove the cartons from the mixed pallet replenishing the correct carton flow slot. This was 5 touches: sort, stage, put-away, retrieve, replenish And their product sat in a dwell state for 2-3 hours. 𝗡𝗲𝘄 𝗺𝗲𝘁𝗵𝗼𝗱: The worker in receiving scans the carton and places it onto a shelf that has been brought to them by a mobile robot...then taken away by the mobile robot. That was 1 touch and 0 dwell time. Product is now live inventory and ready to be ordered. No replenishment necessary. This change saved an average of 5 minutes per master carton. Their smaller-sized operation uses 1,000 master cartons per day. This equates to 5000 minutes per day saved or roughly 10 people. How much is your legacy inbounding process costing you? ===== 📩Send me a message or schedule a meeting in the “featured” section of my profile to find a solution that is right for you. I supply automation technology for fulfillment operations like yours. I am your “easy” button. ♻️Repost if you found this useful.♻️

Shipping costs can drain your margins. But most businesses make the same 3 mistakes. They don't negotiate. They don’t optimize packaging. And they don’t plan for zones. Here’s a quick checklist to get your shipping expenses under control: → Negotiate carrier rates. Most carriers are flexible, especially if you're shipping in bulk. Even small discounts compound over time. → Downsize your packaging. Shipping a 5 lb. product in a 15 lb. box? You’re wasting money on dimensional weight fees. Right-size your packaging to reduce costs. → Leverage regional carriers. Big names aren't always the cheapest. Regional carriers often offer lower rates for short-distance zones. → Optimize your shipping zones. Distribution centers close to your key markets save time and reduce costs. Every mile adds up. → Invest in automation tools. Platforms that compare rates and manage shipments in real-time pay for themselves quickly. Shipping isn’t just a cost—it’s a controllable variable. Small adjustments here = big savings later. Where do you see the biggest gaps in your shipping strategy?

Stop measuring "productivity" and start measuring flow! Most manufacturing metrics focus on productivity - how busy people and machines are. But being busy doesn't mean you're creating value. In fact, maximizing resource utilization often destroys flow and hurts overall performance. Here are 5 flow metrics that matter more than productivity: 1/ Lead Time ➟ How long does it take for material to move from start to finish? ↳ This is the single most important indicator of your process health. 2/ First-Time Quality ➟ What percentage of work is completed correctly the first time? ↳ Rework is the invisible flow killer in most operations. 3/ WIP Levels ➟ How much material is sitting between process steps? ↳ Lower WIP = faster flow and fewer hidden problems. 4/ Takt Adherence ➟ Are you producing at the rate of customer demand? ↳ Neither too fast nor too slow - just in time. 5/ Response Time ➟ How quickly can you detect and resolve abnormalities? ↳ Fast response prevents minor issues from becoming major disruptions. Implementation steps: Step 1: Make these 5 metrics visible in your area Step 2: Reduce batch sizes to improve flow (even if it seems "less efficient") Step 3: Focus improvement efforts on removing flow barriers, not keeping resources busy Remember: A process at 70% utilization with perfect flow will outperform a 95% utilized process with poor flow every single time! --- Follow me Angad S. for more!

CPG brands are losing millions to expired inventory. But with lot tracking, FEFO, and FIFO, you can stop the bleed—if used correctly! 🚀 Lot number tracking is your quality control superhero. When problems arise, locate the exact batch in seconds. FEFO gets fresh perishables flying off shelves while reducing waste and delighting customers. FIFO ensures non-perishables rotate smoothly without gathering dust. Together, these strategies minimize expirations and maximize profits! But remember: implementation matters! A clunky system turns tools into roadblocks. Seek a 3PL partner that integrates effortlessly into your operations—one that truly understands CPG inventory management. Don’t let expired stock cut into your profits. Embrace smart practices for soaring efficiency! Your inventory is crucial; treat it accordingly! #InventoryManagement #SupplyChainEfficiency #WasteReduction #QualityControl #BatchTracking #FreshnessMatters #OperationalExcellence #PerishableGoods #NonPerishableStrategy #LogisticsSolutions

Is Your Inventory Out of Control? If your operation is struggling with: - Stockouts or overstock - Inventory inaccuracies - Poor inventory flow - Unexplained losses - High carrying costs You’re not alone — but there are proven techniques that can help. Here are 5 continuous improvement methods manufacturing and distribution operations use to get inventory back in check: Gemba — Go to where the work happens. Observe problems at the source. Kaizen — Make small, continuous improvements to eliminate waste. Poka-Yoke — Mistake-proof your processes to prevent inventory errors. Kanban — Use visual systems to control stock levels and workflow. 5S — Create a clean, organized, efficient inventory environment. Have you tried any of these techniques in your operation? What inventory challenges are you working to fix right now? Drop a comment — or connect with me if you’re looking for ways to drive real operational improvement. #InventoryControl #LeanManufacturing #SupplyChain #Distribution #ContinuousImprovement #5S #Kanban #Kaizen #Gemba #InventoryAccuracy

Helly Hansen: From Rack to Robot AutoStore Case Study Spotlight - Edition #11 To keep pace with rapid U.S. growth, Helly Hansen transformed its Sumner, WA distribution center with AutoStore™, implemented by Element Logic®. The result? A major leap in scalability, efficiency, and customer satisfaction. This strategic move addressed growth and efficiency challenges and streamlined operations, boosting efficiency and customer satisfaction, a key milestone in Helly Hansen’s quest for operational excellence. Helly Hansen’s rapid U.S. expansion highlighted critical scalability and efficiency challenges. The brand sought a scalable solution to enhance distribution and exceed customer expectations. System Highlights: - 50,000 bins - 36 robots - 10 carousel ports Key Benefits Gained: Faster orders: Order fulfillment time has reduced from 2 or 3 days to just half a day — an 83% improvement. Improved customer satisfaction: Faster delivery times and improved order accuracy have positively impacted the customer experience, reinforcing Helly Hansen's reputation for excellence. Scalability is assured: AutoStore's modular design supports Helly Hansen's future growth, allowing for easy expansion as operational needs evolve. Simpler order handling: AutoStore simplifies various order types, including direct-to-consumer, e-commerce, and complex wholesale. Unified operation: The operation has integrated picking, packing, and shipping. Reduced manual effort: Automation has reduced physical demands on warehouse staff and created a more sustainable working environment. Check out the full case study here: https://lnkd.in/eF-EiSrD #WarehouseAutomation #Robots #SupplyChainExcellence #ASRS #EcommerceLogistics