Warehouse optimisation for a growing healthcare distributor
PTL Co reviewed a space-constrained distribution operation to improve warehouse flow, capacity and productivity without defaulting to costly expansion.
THE CHALLENGE
Creating capacity without simply adding space
Client
Healthcare distribution business
Sector
Pharmacy and healthcare supplies
Scale
2,100 pallet locations, 15,000 orders per month
Engagement
Warehouse optimisation
The client was a growing healthcare distribution business operating from a space-constrained warehouse, with concerns around capacity, congestion and operational efficiency. PTL Co reviewed the end-to-end warehouse operation, supported by order-line data analysis, to determine whether growth genuinely required more space or whether the existing facility could work harder.
The review identified highly manual processes, limited systems control, congestion at peak periods and fast-moving products positioned furthest from despatch. Rather than defaulting to warehouse expansion, the objective was to identify practical improvements to layout, stock positioning, processes and systems that could create a more sustainable operation.
A practical improvement plan that prioritised the changes offering the greatest operational benefit before further investment was considered.
WHAT WE DID
Turning optimisation analysis into practical warehouse improvements
PTL Co combined on-site operational review with detailed order analysis to understand how the warehouse was really being used and where performance was being lost. The work examined storage configuration, product positioning, picking, packing, relabelling and despatch before developing practical changes that could be implemented within the existing facilit
ANALYSE THE OPERATION
Reviewed order data, inventory flows and warehouse activity to understand demand and how work moved through the facility.
REVIEW PROCESSES
Observed picking, packing, relabelling and despatch to identify unnecessary handling, travel and operational constraints.
ASSESS STORAGE
Reviewed racking, pallet capacity and stock positioning to determine how effectively the existing warehouse space was being used
REDESIGN PRODUCT FLOW
Developed a revised layout and stock-positioning approach, including relocating faster-moving products closer to packing and despatch.
PRIORITISE IMPROVEMENTS
Set out practical changes to improve the existing operation before committing to more costly warehouse expansion or investment.
WHAT WE ACHIEVED
Outcomes delivered
The client received a clear, prioritised improvement plan showing how the existing warehouse could operate more effectively before committing to additional space or major capital investment.
Improved product flow
Fast-moving products were repositioned closer to packing and despatch to reduce unnecessary travel and congestion.
Better use of existing capacity
Storage and layout changes demonstrated how the existing facility could support the operation more effectively without simply adding warehouse space.
Reduced unnecessary handling
Changes were identified to simplify labour-intensive activities including inbound relabelling and product handling.
Prioritised investment plan
The recommendations established which operational improvements should be made before considering more costly expansion or systems investment
PTL CO EXPERTISE
Explore related services
Discover the services behind succesful project delivery.
Warehouse operations improvement
Improving warehouse productivity, capacity and flow through practical, evidence-led changes to layout, processes and ways of working.
We focus on changes that improve performance in practice, from smarter stock positioning and picking routes to better use of storage space and warehouse systems.
Could we help your business?
Explore how our experience and proven approach could help you achieve your objectives.
TRUSTED BY LEADING ORGANISATIONS
