As supply chains grow more complex, staying ahead requires continuous refinement of warehouse operations. One of the most effective ways to drive improvement is through regular warehouse reviews. These evaluations go beyond solving immediate problems—they reveal inefficiencies and highlight opportunities to reduce costs, enhance labor productivity, and maximize available space.
Why Conduct Warehouse Reviews?
According to Srinivasan Prasanna, Chief Delivery Officer at iWMS, “Warehouse reviews are essential for optimizing operations by reducing the cost of shipping per package, increasing labor productivity, and making the best use of available space.” These reviews allow businesses to address inefficiencies before they impact bottom lines, especially in markets where space is limited, such as Europe.
Key Focus Areas of a Warehouse Review:
- People – Addressing human challenges, such as height mismatches with shelving.
- Processes – Streamlining inefficient operations that cause delays.
- Tools – Optimizing technology and resources for improved productivity.
Real-World Examples: People, Process, and Tools
In a recent review, iWMS discovered that an employee was struggling to reach high shelves. As Srinivasan puts it, “We cannot stretch a person an extra foot,” so a simple solution was to lower the shelves to eliminate the need for a ladder. Another common challenge involved packaging processes: workers were wasting time cutting masking tape on boxes during picking operations. By having a team pre-cut the boxes, they were able to streamline picking tasks, significantly improving efficiency.
From a process perspective, iWMS discovered that workers were unnecessarily re-scanning totes during picking operations. A simple adjustment – scanning once for 10 picks instead of each time – saved hours of labor. Automation can magnify the impact of such process improvements, ensuring that warehouses run smoother and faster.
Cart Picking: An Example of Efficiency
One of the standout strategies discussed in the warehouse reviews was trolley picking, which allows for multiple orders to be picked simultaneously. Imagine five customers all ordering a similar product – say, lipstick. Instead of sending multiple employees to pick the same item at different times, a cart system allows one worker to pick 10 lipsticks and allocate them to five separate orders in a single trip. As Srinivasan notes, “You maximize efficiency in picking by avoiding unnecessary trips and sorting tasks at the back end”.
Not only does this method save time, but it also reduces the wear and tear on workers who would otherwise have to walk back and forth across the warehouse. By combining technology with smarter manual processes, businesses can significantly improve both productivity and worker satisfaction.
Technology and the Future of Warehouse Reviews
As automation continues to advance, technology will play an even greater role in warehouse operations. One of the emerging trends is Robots as a Service (RaaS), a flexible model where companies lease robots based on operational needs rather than making large upfront investments. This allows warehouses to scale their use of robotics during peak seasons or periods of high demand without the burden of permanent costs.
Robots offer significant benefits in terms of precision and efficiency: they perform repetitive tasks without error and maintain consistent productivity, which is particularly valuable in labor-intensive environments. By integrating automation and robotics into their processes, businesses can standardize operations across multiple locations, creating streamlined workflows that can be easily replicated. This approach not only reduces human error but also enhances overall supply chain reliability and throughput capacity.
With advancements in warehouse management systems (WMS) and robotics, companies are better equipped to handle the increasing demand for faster, more accurate order fulfillment. Automation solutions like RaaS make it possible for businesses to stay competitive in a rapidly evolving logistics landscape, where efficiency and flexibility are key to success.
Continuous Improvement: A Mindset for Success
Finally, successful companies are those that make continuous improvement a part of their culture. As Prasanna says, “Like water in a river, operations need to keep flowing, or they risk stagnation.” A Kaizen approach – focusing on incremental improvements – helps businesses stay competitive by regularly reviewing and refining their processes.
Conclusion
Warehouse reviews are a valuable tool for any business looking to optimize their operations, reduce costs, and prepare for the future. By focusing on people, process, and tools, companies can identify inefficiencies and implement strategies that will not only improve their current operations but also position them for future growth. And with the advent of new technologies like robots and automation, the possibilities for improvement are endless.
Ready to take your warehouse operations to the next level? Contact iWMS today for a comprehensive warehouse review and discover how our tailored solutions can unlock greater efficiency, boost productivity, and future-proof your business.
