Warehouse Operational Improvements

$500M Consumer Goods Manufacturer

Background

  • The company designs, develops, distributes, and manufactures personal hydration solutions, outdoor cooking solutions, action sports helmets and goggles, footwear and cycling accessories, and more
  • Market leader in the industry
  • Distributes products through mass channels and independent bike dealers

Contributions

  • Created SOP for optimizing pallet-build process and trained employees
  • Created SOP for pallet staging process
  • Developed audit checklists for pallet build and staging processes
  • Migrated pallet tracking from manual (Excel) to barcode scanning within the ERP system (SAP)
  • KPI dashboard created with 16 KPIs balanced between leading and lagging indicators

Results

  • Warehouse capacity expanded by 3,532 slots
  • YardviewPro implemented with go-live in 6 weeks
  • Reduced errors caused by manual entry
  • Annual cost savings of over $30k
  • Staged complete units on the dock decreased from 4.5 days to 2.5 days
  • 29% higher average product density on pallets
  • 100% pallet scanning and trackability within SAP