Warehouse Optimization and Logistics

$517M Paper Manufacturer

Background

  • Leading provider of receipt and innovative label solutions
  • Offers complete paper and label solutions to thousands of customers in a variety of industries such as retail, wholesale, manufacturing, banks and credit unions, dining, and transportation
  • The company serves 17 of the top 20 domestic retailers

Contributions

  • Provided talent assessment at the plant and warehouse of existing leadership team
  • Engineered a new layout for warehouse to improve availability of pallet locations by 86%
  • Developed and implemented warehouse metrics and a dashboard to track leading and lagging warehouse KPIs
  • Created and rolled out visual management metrics board to track, share, and communicate KPIs with warehouse team
  • Implemented operational inventory accuracy process for cycle counting

Results

  • The numbers of claims from customers and returns authorizations reduced from 17 to 6
  • On time shipping improved from <90% to 99%
  • Operational inventory accuracy improved from 67% to 93%
  • Productivity improved by 3.2 shipping line per hour and 67.8 units per hour
  • Customer fines improved to $99,000/month from $300,000/month
  • Errors per 10k reduced to 4 from 32