Up to 68%
Turnaround Time Reduction
Faster movement from receiving to dispatch.
Inventory Accuracy & Storage Optimization Consulting
Inventory accuracy drives warehouse efficiency, faster dispatches, and better operational control.
Gemba Concepts helps businesses improve inventory visibility, optimize storage, and build reliable warehouse systems.
India | Middle East | Africa
Talk to Our Experts Today
Results Section
What You Gain
Up to 43%
Storage Capacity Increase
Create more usable storage within the same footprint.
Up to 41%
Material Handling Reduction
Fewer touches, lower damage, and better flow.
Up to 35%
Operational Cost Reduction
Lower warehouse cost per unit handled.
Up to 26%
Manpower Optimization
Improve productivity with the right workforce deployment.
Up to 98%
Inventory Accuracy
Align physical inventory with system records.
Pain Point Section
Is Your Warehouse Losing Control of Inventory?
Inventory records that cannot be trusted
Differences between physical stock and system records create delays and planning issues.
Poor storage utilization
Valuable warehouse space remains underutilized while inventory struggles for locations.
Multiple SKUs stored together
Mixed storage increases picking effort, errors, and unnecessary material handling.
Unstructured rack and location systems
Poor location management slows retrieval, putaway, and inventory tracking activities.
Excessive material handling effort
Products travel longer distances, increasing labor effort and operating costs.
Inventory decisions based on assumptions
Lack of visibility makes replenishment and inventory planning difficult.
Slow putaway and storage processes
Receiving areas become congested when inventory is not stored efficiently.
Weak FIFO discipline
Poor stock rotation increases ageing inventory and avoidable write-off risks.
Solution Section
Where We Help You Succeed
Inventory Accuracy Improvement
Improve stock reliability through cycle counting, location control, and standardized inventory processes.
ABC & Inventory Classification
Classify inventory based on movement, value, and criticality to improve control.
Storage Capacity Optimization
Unlock additional storage capacity through better space utilization and storage practices.
Rack & Location Management Systems
Implement structured location systems that improve inventory visibility and retrieval efficiency.
FIFO & Traceability Systems
Strengthen inventory rotation and traceability across warehouse operations.
Putaway & Storage Optimization
Improve inventory placement and storage processes to maintain accuracy and flow.
Inventory Norm Setting
Define optimal stock levels, reorder points, and safety stock requirements.
WMS Process Optimization
Improve the effectiveness of warehouse systems through better process alignment and data discipline.
Digital Inventory Intelligence
Real-Time Inventory Control & Visibility
Implement QR based putaway and picking, system directed locations and real time stock visibility to the bin level. All movements are recorded automatically, so accuracy of inventory and operational control are assured at all times.
See How It WorksAccuracy
98%
inventory to bin level
TAT
−68%
turnaround time
Capacity
+43%
storage increase
Handling
−41%
material touches
Our Approach
The Gemba Approach
A proven 5‑phase methodology delivered on your warehouse floor — not from a boardroom. Every phase is hands‑on, data‑backed, and measured against a signed baseline.
Assessment & diagnostics
A 2–4 day on-site study. We walk your floor, observe your processes, and find where time, output, and cost are quietly being lost.
Scope, deployment & commercials
Scope defined from your data, not a template. Commercials built on a clear ROI case, so the decision to proceed is grounded in numbers.
Current state mapping & baseline
Every process mapped in detail. A signed performance baseline established — the reference point against which every improvement is measured.
Proof of concept, implementation & on-site training
Solutions validated on the floor before full rollout. Implementation happens alongside your team. Training happens at the Gemba in real conditions, under real pressure.
Sustenance & audit handover
Review systems and audit structures built into your team before we step back. We do not exit on a deadline. We exit when the results hold.
We don't exit on a deadline. We exit when the results hold.
Every engagement includes audit handover and built‑in review systems.
Case Studies Section
Featured Case Study
Real project outcomes across warehouse operations, with measurable accuracy gains and sustained process improvements.
Ceramic Tiles Warehouse
68% TAT Reduction & 43% Storage Capacity Increase
A large ceramic tiles warehouse was struggling with long turnaround times, poor inventory accuracy, and high material damage. Gemba Concepts redesigned warehouse processes, storage systems, and WMS workflows to improve flow, control, and operational efficiency.
68% TAT reduction43% storage capacity increaseInventory accuracy restored
Key Levers
- Warehouse process redesign
- Storage system optimization
- WMS workflow redesign
- Material flow improvement
Fashion Jewellery Distribution Centre
120% Picking Productivity Increase & 38% Space Reduction
A fashion jewellery retailer operating 68+ stores faced low picking productivity, excessive handling, and inefficient space utilization. Through warehouse redesign, inventory slotting, and process optimization, the distribution centre achieved significant gains in productivity and space efficiency.
5.6 → 12.2 items/min17 → 10 touchpoints38% floor-space reduction
Key Levers
- Warehouse redesign
- Inventory slotting
- Process optimization
- Space efficiency
Frequently Asked Questions (FAQ's)
Common Questions, Clear Answers
Everything companies usually ask before starting an Inventory Accuracy & Storage Optimization engagement.
What is Inventory Accuracy & Storage Optimization?
It focuses on improving stock accuracy, storage utilization, and inventory control by creating structured warehouse processes and storage systems.
Why is inventory accuracy difficult to maintain?
Most inventory issues originate from weak processes such as poor location management, unstructured putaway, mixed storage, and inconsistent stock counting practices.
How much additional storage capacity can be created?
Many warehouses can unlock significant additional capacity within the existing footprint through better storage design, slotting, and space utilization.
Do you work with our existing WMS?
Yes. We optimize warehouse processes around your current system and recommend upgrades only when they deliver clear operational benefits.
How long does an inventory improvement project take?
Project duration depends on warehouse size and complexity, but measurable improvements are often visible within the first few months.
Which industries benefit from this work?
Manufacturing, FMCG, retail, e-commerce, pharmaceuticals, building materials, engineering, distribution, and any inventory-intensive operation.
Contact
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