Up to 120%
Picking Productivity Improvement
More orders picked with the same workforce.
Warehouse Process & Operations Redesign Consulting
Better warehouse performance starts with better processes.
We optimize flow, storage, and inventory systems to drive efficiency, accuracy, and growth.
India | Middle East | Africa
Talk to Our Experts Today
Results Section
What You Gain
Up to 81%
Order Processing Time Reduction
Faster movement from receiving to dispatch.
Up to 68%
Vehicle Turnaround Time Reduction
Reduce waiting time at loading and unloading points.
Up to 52%
Orders Processed per Employee
Increase warehouse throughput without adding manpower.
Up to 46%
Warehouse Throughput Improvement
Move more inventory through existing operations.
Up to 41%
Material Handling Reduction
Fewer touches, lower cost, and improved efficiency.
Pain Point Section
Is Your Warehouse Losing Productivity Without Realising It?
Receiving Bottlenecks
Unplanned arrivals, paperwork delays, and poor coordination slow inbound operations.
Inefficient Putaway Processes
Inventory is stored wherever space is available, increasing retrieval time and reducing control.
Slow Picking Performance
Operators spend too much time searching for materials instead of fulfilling orders.
Excessive Material Movement
Multiple handling steps increase operating costs and the risk of product damage.
Dispatch Delays
Poor staging, loading, and documentation processes extend vehicle turnaround times.
Inventory Inaccuracies
Differences between system records and physical stock disrupt operations and decision-making.
Reliance on Tribal Knowledge
Critical processes depend on experienced individuals rather than standardized systems.
Limited Operational Visibility
Lack of meaningful KPIs makes productivity losses and process inefficiencies difficult to identify.
Solution Section
Where We Help You Succeed
Warehouse Process Mapping
Analyze and redesign warehouse workflows from receiving to dispatch.
Receiving & Inward Optimization
Improve truck scheduling, goods receipt processes, and inbound material handling.
Putaway & Slotting Optimization
Establish structured storage logic to improve inventory accessibility and accuracy.
Picking Process Improvement
Optimize picking methods, routes, and execution to improve productivity and reduce errors.
Material Flow Optimization
Reduce unnecessary movement, travel distance, and handling activities across the warehouse.
Dispatch & Turnaround Improvement
Improve staging, loading processes, and vehicle movement to accelerate dispatch operations.
SOP Development & Standardization
Create repeatable warehouse processes that deliver consistent performance across shifts.
KPI & Performance Management Systems
Build dashboards and performance measurement systems to drive operational accountability.
AI-Driven Warehouse Intelligence
Real-Time Warehouse Visibility & Control
Our WMS brings accuracy, consistency and measurability to warehouse operations every day via QR-enabled workflows, real-time inventory tracking and live performance dashboards.
See How It WorksPicking
+120%
productivity improvement
Order Processing
−81%
time reduction
Turnaround
−68%
vehicle time
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 process improvements and sustained performance gains.
Fashion Jewellery
120% Increase in Picking Productivity
A jewellery retail chain serving more than 68 outlets through a central distribution centre redesigned its entire operation — inward, inspection, tagging, packaging, storage, pickup, and dispatch — and integrated ecommerce fulfilment with store distribution. Picking productivity rose from 5.6 to 12.2 items per minute, material touchpoints fell from 17 to 10, and floor-space requirement dropped 38% against the client's own design.
5.6 → 12.2 items/min17 → 10 touchpoints38% floor-space reduction
Key Levers
- End-to-end process redesign
- Inward & inspection optimization
- Integrated ecommerce & store fulfilment
- Material touchpoint reduction
D2C Fashion E‑commerce
Order Processing Time Cut by 81%
A direct-to-consumer fashion distribution centre redesigned its inbound and fulfilment processes, reducing carton-to-rack turnaround from 6.4 days to 1.2, lifting orders per worker from 123 to 188, and cutting average pick-to-pack time from 90 to 59 seconds.
6.4 → 1.2 days turnaround123 → 188 orders/worker90 → 59 sec pick-to-pack
Key Levers
- Inbound process redesign
- Fulfilment workflow optimization
- Picking method redesign
- Carton-to-rack turnaround reduction
Frequently Asked Questions (FAQ's)
Common Questions, Clear Answers
Everything companies usually ask before starting a Warehouse Process & Operations Redesign engagement.
What is Warehouse Process & Operations Redesign?
It is the redesign of warehouse workflows — from receiving and putaway to picking, staging, and dispatch — to improve material flow, reduce handling effort, and increase throughput without adding resources.
How is this different from Warehouse Design & Layout?
Warehouse design focuses on physical infrastructure and storage. Process redesign focuses on how work moves through the warehouse. Both are important, but they solve different problems.
We already have a WMS. Why are operations still slow?
Technology cannot fix inefficient processes. If inventory, workflows, and operating standards are weak, a WMS will only digitize those inefficiencies. We optimize the process first to maximize system effectiveness.
What kind of improvements can we expect?
Typical outcomes include faster turnaround times, higher picking productivity, improved inventory accuracy, lower handling effort, and better utilization of warehouse resources.
Do Gemba Concepts implement improvements on-site?
Yes. Our consultants work directly on the warehouse floor to design, implement, stabilize, and sustain improvements while building capability within your team.
Which industries benefit from Warehouse Process Redesign?
Manufacturing, FMCG, retail, e-commerce, pharmaceuticals, distribution, and any operation looking to improve warehouse productivity, accuracy, and service levels.
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