Building & Layout
Feasibility study aimed at optimizing activities and areas:
- Design of a new building
- Layout design with sizing of the areas necessary for reception, storage, order preparation and shipping
- Redesign of existing buildings with detailed plans of the optimized layout
- Research and verification of existing structures
- Design of internal and external roads
- Evaluation of alternative automation and construction solutions
Solution development:
- Detailed Micro layout (with any additional automation elements)
- Tender for supplies
- Analysis and comparison of the various supplier offers
«Greenfield» building design:
efficient energy plants choice:
• Geothermical system, with underfloor heating
• Photovoltaic system (roof panels, energy lamps, …)
• Insulation (heat loss reduction)
and Building Supervision
Total surfaces
| Warehouse | mq. | 21.000 |
| Offices | mq. | 700 |
| Mezzanine | mq. | 3.500 |
Useful height
| Warehouse | m. | 12,5 e 7,0 |
Achievements
The building respects environment (B energetic class), witha more efficient energetic management
Project activities
• Feasibility study for a new hanging garment warehouse, analysing the company’s current processes
• Warehouse layout design
• Evaluate costs of garment transport and storage systems
• Identification of organizational best practices
Project numbers
• Shipments (1year): 175.000 garpents
• Stock capacity: 6.000 garments
• Warehouse area: 4.000 m2
Achievements
The company wants to increase sales, this requires a more structured shipping process, the operations we have designed have been done to guarantee the company an efficient logistics department.
Organisation
Detailed definition of the organization of the new warehouse:
- definition of the operating logics (inbound, outbound and internal movements)
- sizing of human resources
- definition of operating standards
Ramp-up support for the new “warehouse system”:
- education and training of employees on the new work organization
- setting standards for forecasting and monitoring performance
Projects – Definition of:
• Operational logics
• Human and technical resources management
• Detailed layout
• Technical, equipment and WMS tenders
• Expected investments
• Planning
• Transport planning
and Implementation assistance
Project numbers
| Area | sqm. | 2.000 |
| Useful height | m | 3,40 |
| Pallet places | Nr. | 500 |
| Shelves | Nr. | 1.000 |
| Annual parcels shipped | Nr. | 140.000 |
| Annual picking rows | Nr. | 450.000 |
Achievements
• + 25% operational productivity
• – 15% transport cost
• Service Level improvement
Activities – Definition:
• Analysis of the customer base and selection of priorities
• Mapping of operational processes
• Identification of significant «drivers» for each activity
• «On field» detections and observations of the mapped processes
• Random and repetitive «on field» measurement of times for single activity with the same operating context (processes, layout, equipment,…)
• Determination od Operational standards
• Evaluations about possible savings
• Pricing procedures review
• Assistance during the transition phase between old and new pricing procedure
Project numbers
| Area | sqm. | 260.000 |
| Employees | Nr. | 400 |
| Operational platsorms | Nr. | 9 |
Achieved goals
• 10% not satured hours recovery
• 10% operational costs recovery
Automation
Defining the most suitable automation solutions for the customer:
- Search for innovative solutions characterized by different levels of automation
- Evaluation of the plant’s operational capabilities
- Verification of the adequacy of the solutions to the customer’s service level requirements
Cost benefit analysis:
- Estimate of the investments necessary for the realization of the proposed solutions
- Estimate of the achievable benefits
- Evaluation of returns on investment
Project goals
• Clearence of the old warehouse to allow the expansion of production and packaging area
• Creation of a new finished products warehpouse
Activities – Definition:
• Analysis of storage data and handling flows
• Trend analysis, according to the forecasted business scenarios
• Warehouse areas sizing
• Identification of different plant and organizational solutions
• Qualitative / quantitative comparison
• Choice of the optimal solution: self-supporting automatic warehouse with double-deep shelves
• Detailed design: layout, operational logics, human and technical resources sizing
• Specifications for plant supply
• Specifications for the new Information System
• Design of the transitional phase
• Implementation plan
Project numbers
| Storage capacity | PP | 36.000 |
| Total height | m | 36 |
| Stacker cranes | Nr. | 8 |
| Payback time | Years | 3,5 |
Achievements
• +50% possible increase in production capacity
• 80 % recovery of the operational costs for the external movements
Material Handling
Definition of material handling systems:
- Define the most suitable handling systems for the type of products and operational flows
- Definition of systems and equipment
- Definition of the internal transportation equipment
Cost and benefit analysis:
- Estimate of the necessary investments for the purchasing of equipment and operational systems
- estimate of the achievable benefits and evaluation of returns on investment
Specifications for supply:
- Supplier specifications for the purchasing of systems and equipment
- Analysis and comparison of supplier offers
Support during implementation:
- tender bids to suppliers
- evaluation of the offers received
- coordination on site and during implementation
Activities – Definition:
• Check-up of the current situation and selection od the main «Customers» for the individual HUBs (Land-Air-Ocean)
• Mapping of handling flows and macro operations processes for HUB / customer (STD activity)
• Identification of the significant «drivers» for each activity
• Detection format creation
• Mapped processes check, sharing and «on field» refinement
• Random and repetitive «on field» measurement of times for single activity with the same operating context (processes, layout, equipment,…)
• Determination od Operational standards
• Evaluations about possible savings
• Pricing procedures review
• Assistance during the transition phase between old and new pricing procedure
Project numbers
| Area | sqm. | 38.000 |
| Employees | Nr. | 130 |
| Annual Shippings | Nr. | 500.000 |
| Annual parcels shipped | Nr. | 3.800.000 |
| Weight | Kg | 200.000.000 |
Achievements
- 18,0 % not saturated hours recovery
- 15,5 % operational costs recovery
- 15,0 % recovery of the cost for the transport of 0,1ton
Project objectives
• Evaluation of the correct location and shape of the building within the available area
• Evaluation of future expansion opportunities
• Definition of the structure of the building, based on specific logistical needs
• Evaluation of alternative solutions, characterized by the introduction of handling systems with different automation levels
• Optimization and rationalization of flows
Activities– Definition:
• Analysis of stock and handling flows
• Sizing of individual warehouse areas
• Identification of automation solutions (sorter, miniload) and alternative organizational solutions
• Comparison between the alternatives in terms of quality and costs
• Selection of the optimal solution
• Detailed design: layout, operating logic, human and technical resources sizing
• Plant supply specifications
• Technical specifications of the new WMS
• Project implementation plan
• Assistance and coordination during the implementation
Progetto in cifre
| Area | sqm. | 37.000 |
| Warheouse height | m | 12,5 |
| Payback | Years | 3,2 |
Achievements
• -22% of logistic costs
• x4 of shipping volumes
• -15% of warehouse areas
• 24h lead time
Information technology
Operational system definition:
- Detailed design of the warehouse organization system
- Definition of the appropriate information system to support the work organisation
Functional specifications for suppliers:
- Definition of functional specifications for supplier tenders
- Comparison of the various offers received from suppliers
Support during implementation:
- launch of tender bids to suppliers
- evaluation of the offers received
- coordination on-site and during implementation
- assistance in implementing WMS changes
Project objectives:
• Re-engineering of the distribution centre
• Evaluation of the various automation offers
• Drafting of the functional specifications for the WMS and WCS
• Implementation support
Project numbers:
• Miniload: 60 pallet/h in & 60 pallet/h out
• Preparation of 300 pannels/h
• 1200 mq of automated pick locations
Achievements
Increase in warehouse efficiency by moving from an entirely manual system to a manual-automatic mixture, leading to standardization of processes and a faster order fulfillment.
Project objectives:
- Analysis of the current situation with mapping of the processes
- Shared acceptance of the proposed solution (tender grid).
- Tender with technical and economic specifications updated.
- Drafting of SW&HW technical specifications for the WMS
- Assistance in the implementation phase of outsourcing services, and project management
- Drafting of new operating procedures and job descriptions
Project numbers
| Area: | sqm. | 26.000 |
| Height: | m. | 11 |
| Pallet places: | nr. | 10.000 |
| Pieces shipped (1year): | nr. | 2,5 millions |
| Operativity | gg. | 24/7/365 |
| FTE blue collar (min-max): | nr. | 60-80 |
Achievements
• -20 % logistic cost (handling and transportation)
• +15 % productivity of employees (operational tasks, tools and transport, WMS)
• Introduzione di cruscotti di controllo e KPI (in tempo reale su APP)
Transport & distribution
Distribution network definition:
- Definition of the transport system and the distribution network consistent with the level of service
- Identification of the distribution map centre
- Definition of travel optimization systems
- Study of the costs of the new system and comparison with current costs
- Estimate of the achievable benefits
Project activities:
- Finding a suitable location for a new warehouse
- Optimize transports, distances and increase the level of service
- Define the sizing of the warehouse
Project numbers:
- 715 shops served around Italy
- 130 M of Kg distributed yearly
Achievements
Significant reduction in travel distances from the location of the new warehouse analysed with our distance calculation software
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