Without a structured process there is no reliable data, and no reliable AI.
Before any work on data or AI starts, we bring order to how the work really happens today: on the floor and in decision-making.
Many programmes start too early
Many companies start straight away with a dashboard or AI tool while the process underneath is not stable. The result: inconsistent data, workarounds that nobody documents, and an AI project that "doesn't work", while the real problem was in the process.
From waste to a fixed standard
Every warehouse process has the same waste: waiting, walking, searching, errors and double work. First we measure where they are. The biggest ones are tackled and the new way of working is recorded, so they do not come back.
From the dock to the invoice
Every process with recurring steps and measurable data can be improved. These are the processes where gains are most often found in a warehouse or distribution centre.
See. Solve. Sustain.
Choose a step to see the analyses a client receives. Every analysis is based on measurements on the floor and in your systems.
Walking route: how far do your people walk?
The route of one order on the floor plan, before and after rearranging. In this example from 620 to 160 metres per order.
Result from practice: +30 % productivity by rearranging the workplaceWhat you get
The walking distance per order in metres, before and after, and the places with the biggest detours.
Full explanation on the Solutions page →Order flow: where does the order build up delay?
An order followed from receiving to loading, together with the processes that affect it, such as the release, replenishment and the transport planning. That shows where the order waits, where the delay builds up and which other process causes it.
Result from practice: waiting-time penalties virtually goneWhat you get
The total lead time, the part that is real work, the delay that builds up per step, and the links with other processes that cause the delay.
Full explanation on the Solutions page →Time measurement: how long should a handling step take?
Every handling step is broken down into small steps, with a fixed time per step from a standards table. That way you know how many seconds an order line may take, and where the rest of the time goes.
Result from practice: +50 % output per labour hourWhat you get
A standard per handling step and per order line, and a staffing level per hour that matches the work.
Full explanation on the Solutions page →Cost per process step: do you earn money on every handling step?
The measured time converted to euros per pallet, next to the rate the customer pays.
What you get
The cost, the rate and the difference per process step, so it is clear where money is lost.
Full explanation on the Solutions page →Finding the cause: all causes and five times why
All possible causes listed, then five times why for the biggest one. That way the root cause is tackled.
What you get
The root cause of the problem, with the measure that removes it.
Full explanation on the Solutions page →Risk analysis: what can go wrong?
Every possible error gets a score for likelihood, impact and detection. The measures go to the highest score first.
What you get
A list of the risks with their score, before and after the measure.
Full explanation on the Solutions page →Workplace organisation board
A short audit per zone every week. Green from 85 %, with one problem of the month.
What you get
A board per zone, an audit checklist and an approach in five steps, starting in one pilot zone.
Full explanation on the Solutions page →Daily board per shift
Every hour planned versus done, with the reason for any difference, the tasks and the hand-over.
What you get
A board per shift and a ten-minute daily huddle, on paper or on a screen.
Full explanation on the Solutions page →Action plan
Every measure gets an owner, a deadline and a status, and is reviewed every week.
What you get
An action plan that is followed up until every measure is done.
Full explanation on the Solutions page →Does the improvement hold?
After the improvement, measurements are taken every week. If a point falls outside the limits, an alert follows.
What you get
A chart with limits per KPI, so you can see whether the improvement holds.
Full explanation on the Solutions page →An improvement only works when the team carries it
Every improvement programme takes the team along in five steps. That way the team understands why something is changing, wants to take part, knows how to do it, is able to do it, and it stays that way.
A short explanation at the start, with the figures from the measurement.
The team measures along and says what annoys them most.
Work instructions and training for the new way of working.
First one pilot zone, as an example for the rest, with support on the floor.
A daily huddle at the board and follow-up until the new way of working sticks.
Improvement programme
Tackle one process thoroughly, from measuring to sustaining. The programme always starts with the quick scan, so it is clear which process delivers the most.
The scope and the planning are agreed with you at the start. You receive a tailored quote in advance.
Request a quote- Walking the floor and measurements from your WMS
- The analyses that fit the problem: walking route, order flow, time measurement or cost per step
- Improvements together with the team, tested on the floor
- A board and a dashboard to sustain it
- A hand-over, so your people continue the follow-up themselves