100K
SKUs managed
Luxury Eyewear Warehouse Optimization Saves $1.2M
Optimized picking and sorting strategies through dynamic warehouse simulation, reducing automation payback time and delivering $1.2M savings. EFESO supported one of the world’s largest luxury eyewear portfolios in optimizing its U.S. lens distribution center operations, handling more than 100,000 product references with a dedicated team of 80 employees.
Consumer Goods and Luxury
Operational Excellence
Operations Strategy and Transformation
Supply Chain
Our Client
A global luxury eyewear group managing one of the world’s largest portfolios in the fashion and optical markets. The collaboration focused on its U.S. lens distribution center, a high-volume facility managing over 100,000 product references and employing 80 people.
80
Dedicated workforce
The Challenge
The client aimed to define the most effective picking and sorting strategies to achieve rapid automation payback within its lens distribution center.
• Optimization of picking and sorting parameters: Need to identify the best combination of picking policies, sorting technologies, and parameter settings.
• Dynamic warehouse simulation requirement: Rapid simulation of warehouse operations based on forecasted volumes.
• Area segmentation and process variation: Evaluation of multiple warehouse zones and operational configurations.
• Payback time reduction: Necessity to deliver measurable savings within a short time frame.
Real Results Achieved Together
The optimization program enabled the client to identify the optimal picking and sorting configuration through dynamic simulation, accelerating automation ROI and improving operational efficiency. The project also developed rules for order bundling, defined a simulation model for picking sizing, and established a set of operational parameters for efficient warehouse performance.
$1.2M
Savings foreseen
$0.8M
Savings in the first year
2
Years total payback period
Transformation Impact
- Shortened payback period for automation investments.
- Developed order bundling rules aligned with sorting technology.
- Created a flexible simulation model reflecting different pathways and picking approaches.
- More than one million in savings projected in two years through optimized operations.
Our Approach
EFESO applied a structured simulation-based approach to evaluate and select the optimal picking and sorting strategies.
- Order and Service Level Analysis
• Analyzed order cut-off time consistency versus service level, focusing on daily operational peaks.
• Reviewed significant data samples to ensure operational feasibility and service alignment. - Simulation Modeling and Testing
• Built a detailed simulation model representing pick and pack operations (manual and automated).
• Evaluated multiple area segmentations, picking modes, and technology options. - Stakeholder Alignment and Decision-Making
• Facilitated discussions with key stakeholders to compare picking policy alternatives.
• Reached consensus on the configuration that minimized automation payback time.
Related Services
Supplier complexity obscures 70% of your value creation. We strengthen networks through supplier development programs, risk mitigation strategies, and collaborative innovation platforms.
Ready to Transform Your Warehouse Operations Into a Competitive Advantage?
- Unlock millions in savings through optimized automation strategies that pay back faster
- Stop guessing which warehouse improvements will actually move the needle on profitability
- Join leading manufacturers who’ve cut payback time while maximizing operational efficiency
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