The Situation
Floor-stacking operations increased touches for heavy, fragile SKUs, inflating both delay and breakage risk.
Locations were improvised, inventory confidence was low, and dispatch started as a search activity.
Speed and damage looked separate but originated from excess handling.
What We Did
We redesigned the warehouse for lower-touch movement and safer, denser storage.
- Redesigned storage systems for density plus product protection.
- Rebuilt inward-to-dispatch flow to eliminate handling steps.
- Reworked WMS workflows to improve stock location certainty and count reliability.
The Results
Turnaround time reduced 68% and storage capacity increased 43% in the same building footprint.
Inventory became reliable, and product damage reduced due to fewer touches.
Strategic Takeaway
- Speed and breakage are usually a shared handling problem.
- The fastest warehouse often wins by moving less, not moving faster.
Contact Gemba Concepts
Need Help Solving Similar Execution Gaps?
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Bengaluru
Ram Leo, 59/4, Market Rd, Basavanagudi, Karnataka 560004
Ahmedabad
World Trade Tower, Near Sarkhej Sanand Cross Road, Gujarat 380051
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