8
Large-scale warehouses across the US
Redesigning Warehouse Operations to Cut Cycle Time by 87% and Boost Throughput by 30%
EFESO collaborates with major North American retailer to redesign warehouse operations, transforming omni-channel fulfillment through enhanced throughput capacity, improved DTC responsiveness, optimized inventory flow and reduced processing costs across 8 large-scale distribution centers.
Industry: Retail
Service: Manufacturing
Service: Supply Chain
Our Client
A major North American apparel and lifestyle retailer operating a complex omni-channel supply chain.
+7.4K
Customer ship-to locations, including retail stores and e-commerce buyers
The Challenge
The client manages a product portfolio with high seasonal variability and frequent promotional events, as well as a a network experiencing rapid shifts in consumer buying behavior post-pandemic, increasing the need for fulfillment agility and labor cost control.
The initiative was driven by the need to increase throughput capacity, enable better DTC responsiveness, and improve inventory flow while reducing processing costs in a labor-constrained market. Key challenges included:
- Accelerating processing costs per case
- Limited direct to consumer ability
- Locations “Slot Locked”
- Elongated order to ship cycle times
- 3 adjacent overflow inventory locations
Real Results Achieved Together
EFESO redesigned omni-channel warehouse operations, cutting order-to-ship cycle time by 87% and increasing throughput capacity by 30%.
$12M
Projected annual savings
87%
Reduction in cycle time
30%
Improvement in capacity/ throughput
Transformation Impact
- Redesigned omni-channel warehouse operations
- Cut order-to-ship cycle time from 48 hours to 6 hours
Our Approach
- Redesigned inbound order flow to level load seasonal builds
- Split customer order drop from 1 to 4 times daily
- Adjust labor shift schedules
- Increase part-time labor force mix
- Change outbound shipping patterns
- Re-organize regional customer to warehouse location assignments
- Implemented ware hose quarterly re-slotting
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Facing Similar Challenges?
- Operate complext omni-channel supply chains and increase throughput capacity.
- Enable better direct-to-consumer responsiveness.
- Improve inventory flow and reduce processing costs.
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