Issues
The client was a leading consumer goods manufacturer expanding into high-volume e-commerce fulfillment. Manual warehouse operations could no longer keep pace with rising order volumes and complex SKU profiles. The leadership required a smart warehousing strategy integrating automation technologies to improve efficiency, reduce errors, and prepare for future digital transformation.
Solution
We developed a smart warehouse blueprint incorporating automation technologies such as ASRS, AMRs, pick-to-light systems, and advanced WMS modules. The solution balanced cost, scalability, and operational needs. Automation simulations evaluated potential throughput gains and labor reduction impacts. The strategy positioned the company to adopt automation systematically over a phased roadmap.
Approach
- Assessed current warehouse operations and identified automation readiness gaps.
- Conducted technology benchmarking across global best practices in smart warehousing.
- Modeled throughput improvements using multiple automation configurations.
- Developed a phased automation roadmap aligned with volume projections and ROI targets.
- Evaluated WMS integration requirements supporting advanced warehouse technologies.
Recommendations
We recommended deploying AMRs for order picking, introducing ASRS for high-velocity SKUs, and integrating pick-to-light systems to reduce human error. We also advised redesigning storage layouts for automation compatibility and upgrading the WMS to support real-time synchronization with automation equipment.
Engagement ROI
Order processing speed increased by 40%, error rates dropped by 35%, and labor productivity improved by 30%. The client achieved a projected payback period of fewer than four years, with automation readiness enabling substantial long-term operational resilience.