Shortening order picking time by 37.4% for a construction wholesaler
We rebuilt the aisle layout and implemented a simple segregation method for fast-moving goods. Workers now walk 4 km less per day.
Bud-Gdańsk wholesaler struggled with shipping delays and a high number of errors. We implemented a new goods arrangement plan that shortened packing time by over one-third without buying expensive software.
The challenge
In March 2024, the company recorded 218 dispatch errors, costing them 14,300 PLN in returns alone. Warehousemen wandered aimlessly through the 2,400 m2 hall, looking for small accessories hidden behind concrete pallets. The average time for picking one order was 22 minutes, which paralyzed the afternoon shift's work at 187 shipments per day. Employees were exhausted, and overtime costs in April reached 9,840 PLN.
Our approach
The Baltic Strategy & Development team conducted an audit 'with pencil in hand'. For 11 days, we measured the distance traveled by 6 workers using pedometers. It turned out that one warehouseman walked an average of 9.4 km per shift. We identified 43 product groups that accounted for 78% of turnover but were located in the farthest corners of the warehouse. Numbers don't lie – the plan was simple: move the goods closer to the ramp.
The solution
We changed the layout of 14 high-bay racks, creating a so-called 'fast zone' right at the exit. We introduced a color-based aisle numbering system, which eliminated the need to ask the manager for the location of small parts. Additionally, we installed 3 new packing tables with ready-made sets of film and tape at hand. We cut unnecessary movements in the warehouse, so we also designated one-way paths for forklifts, ending congestion at corners.
Results
Thanks to the changes, warehousemen now walk 4.1 km less every day. The company stopped paying for Saturday overtime, and customers receive goods one business day faster.
Timeline
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April 2024Distance and work time measurements for 6 warehouse workers.
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May 2024Regrouping of 43 most frequently sold goods.
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June 2024Installation of new packing stations and hall signage.
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July 2024Verification of results and training on the new warehouse map.
"Instead of theory, we got a concrete plan. Warehousemen initially grumbled about the changes, but now they see for themselves that they tire less, and work gets done faster."