Case Studies
Real-world Success Stories
Displaying 7 Results for: ALL CASE STUDIES
10X Scale & Optimize Fresh Cold-Chain Veg DC
An India-based B2B Agri Tech marketplace aimed to scale its operations 10X through a new distribution center, focusing on validating layout efficiency, identifying bottlenecks, optimizing space and dock usage, and ensuring readiness for diverse truck loads
Solution Highlights
- ▶Streamlined material flow within the DC to minimize movement
- ▶Analyzed storage utilization and allocated zones for different SKUs
- ▶Pinpointed process bottlenecks and proposed automation with ROI-backed recommendations
- ▶Redesigned dock planning for smoother truck turnaround and balanced load handling
- ▶Devised 3-shift workforce model to ensure round-the-clock operational efficiency
Outputs Delivered
- ✓Real-time SKU tracking logs with timestamp visibility
- ✓Higher space utilization through smart reallocation of storage zones
SKU Slotting with Order Release Logic Creation & Validation
A leading U.S. manufacturer needed to optimize SKU slotting and order release logic at pick stations - ensuring cartons were processed efficiently and within strict time limits by operators
Solution Highlights
- ▶Classified high and low-runner SKUs based on real-time demand across pick stations, ensuring balanced workloads and optimal slot allocation
- ▶Designed order release logic for 50+ SKUs per station, enabling seamless processing of 16K+ orders daily & validated with Simulation
- ▶Incorporated dynamic variables such as conveyor speeds, operator travel, and handling times to accurately reflect real-world operations
Outputs Delivered
- ✓Comprehensive process logs tracking every carton, operator, and station event with timestamps
- ✓Validated multiple WMS logics, recommending the optimal configuration for operational efficiency
- ✓Optimized SKU replenishment windows to ensure smooth rack operations and zero bottlenecks
Operator validation in the manufacturing unit
Throughput & operator validation of as-is scenario in a medium scaled US medical manufacturing industry
Solution Highlights
- ▶Inputs directly imported & results exported to the excel
- ▶Simulated with variable parameters of operators, dynamic allocation of tasks, area restrictions & shift conditions, by keeping all the parameters dynamic to optimize the current scenario
- ▶Dynamic parameters for each value that can be modified by the user
Outputs Delivered
- ✓Propose optimized scenario for the future manufacturing
- ✓Detailed logs of each operator & utilization
Design and throughput validation of the conveyor setup
Design & throughput validation of the high-speed conveyor system handling the UK based fast-food processing
Solution Highlights
- ▶Simulated the system with 10+ SKUs, Pick and Place robots capability with one week of order history
- ▶Model developed with variable parameters of conveyors, robots handling times etc. by keeping all the parameters dynamic for the user to update the scenarios prior to design finalization
- ▶Reduced the lead time for the team from design to implementation
- ▶Bottleneck areas were identified and corrective measures introduced & validated the same in the environment
Outputs Delivered
- ✓Detailed logs of each SKU & tray with the timestamp at every instance
- ✓Robots utilization and suggested steps for optimization
Design validation of PnP and Palletizer robots
Design validation of the Pick and Place [PnP] and palletizer robots handling the package of UK based fast-food manufacturer
Solution Highlights
- ▶Simulated the high-speed conveyor palletizing line with 10+ SKUs, 10+ pick patterns & layer patterns based on the peak order history
- ▶Model developed with variable parameters of conveyors, recipes, robots & palletizer handling times etc. by keeping all the parameters dynamic
- ▶Reduced the lead time for the team from design to implementation
- ▶Modeled with Inputs directly imported & results exported to the excel
Outputs Delivered
- ✓Detailed logs of each carton with the timestamp at every instance
- ✓PnP robots & Palletizer utilization, log of each movement & recommendations to improve the efficiency
Boosting Steel Mill Efficiency without Expansion
A medium scaled India-based steel plate rolling mill aimed to boost production within its existing plant by validating rolling plan efficiency and bed utilization, Maximizing truck loads from a single bed.
Solution Highlights
- ▶Analysed furnace utilization across varying conveyor speeds and steel grades
- ▶Identified bottlenecks in plate flow and process timing
- ▶Optimized truck loading by clubbing customer orders
- ▶Defined smart slab-launch logic to minimize grade changeover time
Outputs Delivered
- ✓Real-time slab and plate tracking with timestamp visibility
- ✓Improved throughput through efficient grade changeovers and load planning
Throughput validation of the packaging setup
Throughput validation of the conveyor system & shuttle car handling pallets for the Europe based dairy processing industry
Solution Highlights
- ▶Modeled palletizing line with 100+ SKUs, 20+ layer patterns
- ▶Developed with variable parameters of conveyors, various scenarios for the carton diversions into the lanes, shuttle car pickup priorities etc.,
- ▶Dynamic parameters for each value that can be modified by the user
- ▶Inputs directly imported & results exported to the excel
Outputs Delivered
- ✓Detailed logs of each carton, robots & palletizer with the timestamp
- ✓Robots utilization and recommended optimal pickup priority
- ✓Shuttle car utilization with the optimal pickup of pallets from the lane
- ✓Occupancy of the lanes & rejection carton analysis