100K
SKUs managed
Luxury Eyewear Warehouse Optimization Saves $1.2M
Industry: Consumer Goods and Luxury
Service: Operational Excellence
Service: Operations Strategy and Transformation
Service: 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
$1M
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
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Supply Chain
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
Discover More Clients Results
20%
Increase in productivity
Resources Mining and Processing
Transforming Mining Operations Through Predictive Analytics and Equipment Performance Improvements
A leading mining company improved mine planning efficiency, equipment utilization, and operational performance through integrated planning systems, predictive maintenance, and real-time monitoring technologies.
20%
Downtime reduction
Industrial Manufacturing
Improving OEE and Production Oversight Through Digital Transformation
A die-cast metal manufacturer improved equipment effectiveness, reduced downtime, and increased operational visibility through predictive maintenance, IoT integration, and real-time production monitoring.
20%
Operating cost reduction
Industrial Manufacturing
Resources Mining and Processing
Delivering Sustainable Mining Performance Through Operational Excellence
A mining company reduced operating costs by 20% through improvements in pit-to-plant planning, asset performance, maintenance reliability, supply chain management, and operational accountability.
15%
Operating cost reduction
Resources Mining and Processing
Reducing Mining Operating Costs Through Operational Excellence
A mining company reduced operating costs by 15% by improving pit-to-plant coordination, maintenance effectiveness, supply chain performance, and operational accountability through a high-performance operating system.
60%
Reduction in workplace accidents
Industrial Manufacturing
Resources Mining and Processing
Improving Safety Performance Through Real-Time Monitoring and Workforce Engagement
A leading mining company improved workplace safety and operational visibility through real-time monitoring systems, digital safety management tools, and targeted workforce training initiatives.
25%
Reduction in project delays
Industrial Manufacturing
Resources Mining and Processing
Building a Digitally Enabled CAPEX PMO for Better Project Performance
A major mining company implemented a centralized CAPEX PMO with digital reporting tools to improve governance, cost control, project visibility, and execution consistency across its capital project portfolio.
$12M
Projected annual savings
Retail
Redesigning Warehouse Operations to Cut Cycle Time by 87% and Boost Throughput by 30%
Redesigned omni-channel warehouse operations, cutting order-to-ship cycle time by 87% and increasing throughput capacity by 30%.
$6.5M
Annual margin gain through increased crude throughput
Oil & Gas, Sustainable Energy
Improving Crude Throughput by 25% via Lean Process Optimization
Eliminated naphtha bottleneck through lean optimization, accelerating crude throughput 25% and capturing $6.5M margin gain.