Future-Ready Warehouse Management Solutions

End‑to‑end Warehouse Management implementation by Ex‑Toyota TPS experts from layout and processes to WMS, executed on‑site until results are embedded.

99.9%

Achieve

Inventory Precision

60%

Dispatch

Lead-Time Reduction

500+

Clients

40+

Sectors

100%

Customized Solution

2CR+

Sqft Warehouse Design

11+

Years of Experience

Is It Time to Upgrade Your Warehouse Management?

Growth is quietly being held back by warehouse inefficiencies.

1. Clogged docks, delayed GRNs, and poor layouts choke throughput when capacity is most needed.

2. Stockouts damage customer trust while dead stock ties up cash.

3. Manual processes keep teams firefighting, increase labour dependency, and create errors.

4. Without real‑time visibility, decisions are made on reports, not control.

5. Poor FIFO and quality rework eat into the capacity meant for growth.

While your warehouse struggles, agile competitors run data‑driven, Warehouse Management System. Losing speed in a market that rewards speed is the real risk— not inefficiency.

Our Solutions

Full-Time On-Site Deployment

Our Consultants work Full Time On-Site,
ensuring real-time Decisions & precise Execution where it actually matters.

Execution On The Shop Floor

We work directly on the Shop Floor, Solving problems as they Happen
not after reports are reviewed.

Until Results Are Embedded

We stay until improvements are Implemented, Stabilized and Embedded into Daily Operations — only then do we hand over.

Warehouse Management Solutions We Offer

📐

Warehouse Layout & Infrastructure

Design & Visualization

With 2D/3D visuals for optimal space planning and workflow efficiency.

📊

Inventory Optimization

Analysis & Strategy

Via ABC analysis and strategic slotting for maximum inventory control.

💻

WMS Framework Development

Custom Solutions

Requirements, wireframes, and validation for customized warehouse management.

🏗️

MHE & Racking Ecosystem

Selection & Implementation

Strategic selection for optimal space utilization and material flow.

👥

Manpower Planning

Optimization & Management

With standards, KPIs, and organograms for workforce optimization.

See What’s Possible for Your Business

Real Time Impact

Warehouse Management Benefits: Measurable Results

At Gemba Concepts, we empower businesses to achieve operational excellence through customised lean strategies, practical process improvement solutions, and hands-on execution designed to drive measurable results.

Improve Productivity By

50%

Improve Thru-Put Time By

40%

Boost Output & Efficiency By

15%

Improvement In Fulfilment Ratio

10%

Proven Results in Chemical Retail Ceramic Industry

Case Study

How a Ceramic Industry Warehouse Reduced TAT by 69% and Manpower by 26%

The Challenge

High Packaging Material (PM) Inventory Holding Cost
Low Manpower Productivity
Finished Goods (FG) Shortfall due to Ineffective Production Planning
Lack of Process Standardization
Inefficient Layout & Excess Material Movement
Manual Logbooks & Limited Visibility

What We Changed

Analyse:
Understanding end-to-end warehouse flow — Value Stream Mapping — Spaghetti Diagram — Time & Motion Study — Inventory Ageing Analysis — Bottleneck Identification — Capacity Calculation

Design:
Lean inward and outward flow redesign — Optimized racking layout to increase storage density — Single-bin single-product system — Centralized loading point — New pallet standardization — WMS integration for digital inventory control

Reallocation & Sustain:
Infrastructure build (racking & dock levelers) — Poka Yoke to reduce breakage — WMS-based inventory mapping — QR scanning system — SOP creation & workforce training — Proof of Concept validation (milk runs) — Sustaining standardized workflows

The Challenge

High truck turnaround time due to waiting, multiple loading points & Documentation Delays
Inefficient Storage With Multiple Products Per Bin & Low WMS Accuracy
Excessive Pallet Handling & Poor Material Flow
High Breakage & Manpower dependency
Poor Inventory Visibility Driven By Manual Systems

Business Impact

Real-Time Inventory Tracking With WMS-Enabled Visibility
Reduced Handling Touchpoints & Centralized Dispatch Control
Scalable Warehouse Capacity With Higher Storage Efficiency
Lower Operational Costs & Breakage Control
Digitally Driven & Standardized Warehouse Operations

The Results

Significant reduction in product damage, with breakage falling from 41 boxes to 1 box in trials.
43% Improvement in Storage Efficiency

35%

26%

69%

Reduction in Operational Cost

Manpower Reduction

Truck TAT reduction

Case Study

Driving Efficiency Through Digital Transformation in Warehouse Operations

The Challenge

High product touchpoints across fulfilment stages
Low orders processed per person
Inefficient material movement within the warehouse
Inventory imbalance and capacity constraints
Process bottlenecks impacting order flow
Lack of standardized layout and manpower structure

What We Changed

Analyze: Material Movement Study — Storage Pattern Analysis — Picking & Dispatch Delay Study — Inventory Ageing — Inventory Turnover — Workflow Gap Assessment — Manpower Dependency — Rack Utilization — BIN Mapping

Design: WMS Customization — QR Traceability System — Critical-Based Putaway — BIN Assignment Logic — Auto & Manual Picklist Design — Single & Bulk Pickup Flow — SKU Lookup System — Bin-to-Bin Transfer Design — Real-Time Inventory Dashboards — Power BI Monitoring — Visual Rack Management

Reallocation & Sustain: WMS Deployment — Standardized Inventory Audits — Bin Consolidation — ERP Integration — Digital Workflow Training — Real-Time Tracking — Reporting Sustainment

The Challenge

Lack of real-time material traceability
Significant time wasted in searching for materials
High manpower involvement in material fetching
Material ageing issues
Delayed delivery to stores
Low visibility of inventory movement
Manual tracking causing operational delays

Business Impact

Reduced Dependency On Manual Processes
Faster & More Accurate Material Movement
Improved Inventory Visibility
Enhanced Picking & Storage Efficiency
Optimized Warehouse Space Utilization
Scalable Digital Infrastructure For Expansion
Better Decision-Making Through Live Dashboards

The Results

Significant Reduction in Manpower Dependency
Full Real-Time Visibility of Inventory
Faster Order Processing
Improved Inventory Accuracy
Better Space Utilization
ERP + WMS Integration Enabled
Scalable Multi-Warehouse Operations

80%

60%

Reduction in Material Search Time

Improvement in Turnaround Time

Case Study

How a Pharmaceutical Distribution Company Improved Productivity by 40% in 12 Months

The Challenge

High Work In Progress (WIP)
Long & Unpredictable Manufacturing Lead Time
Low Reactor Utilization
Recurring Bottleneck
Reactive Maintenance Downtime
Fragmented Production Planning

What We Changed

Analyze: Process Mapping — Gemba Walks — Material Movement Study — Time & Motion Study — Value Stream Mapping — Spaghetti Diagram — Bottleneck Analysis — Inventory Analysis

Design: Digital Process Conversion — Layout Optimization — Standardized Workstations — Manpower Balancing — Load Balancing — Proof of Concept (POC) Validation

Reallocation & Sustain: SOP Implementation — 5S System — Visual Management — Process Audits — Team Training — Continuous Improvement Practices — Sustainment Framework

The Challenge

Low productivity and throughput time
High manpower dependency
Inefficient material movement
Inventory mismanagement
Process bottlenecks
Lack of standardized workflows
Poor Layout Utilization
Limited Cost Optimization

Business Impact

Higher productivity & Throughput
Reduced Manpower Dependency
Improved Order Fulfillment Accuracy
Better Inventory Control & Standardization
Optimized Layout & Workspace Utilization
Enhanced Operational Visibility
Cost-Efficient & Scalable Operations

The Results

Improved Layout Design
Standardized Inventory Management
Visually Organized & Efficient Facility

40%

35%

10%

Improvement in Productivity

Improvement in Throughput Time

Reduction in Headcount

2D & 3D Warehouse Layout And Design

500+ Trusted Clients

Our Clients

Why They Chose Us — & What Followed

“Gemba Concepts’ consultants work directly on the shop floor, which allows them to gain a deep understanding of our processes, challenges and opportunities.This hands-on approach has resulted in practical and tailored solutions that have reduced wastage, optimized processes, and increased overall equipment effectiveness (OEE).”

"Gemba Concepts demonstrated exceptional expertise in reducing operational bottlenecks, optimizing stock movement, and implementing data-driven inventory management."

“Throughout the project, they demonstrated exceptional expertise in implementing lean methodologies, reducing inefficiencies, streamlining production practices, and deploying technology-driven solutions for inventory control. Their contributions enabled us to improve service levels, optimize costs, and ensure seamless daily operations, while fostering a culture of continuous improvement.”

“The expertise and professionalism of the Gemba Concepts team have resulted in substantial cost savings. Their automation strategies have optimized our workflow and helped us to reduce waste & build a robust production management system.This focus on reducing waste has not only lowered costs but has also supported our commitment to sustainable business practice”

“Gemba Concepts demonstrated exceptional expertise in implementing lean methodologies, reducing operational inefficiencies, streamlining warehouse management practices, and deploying technology solutions for maintenance tracking and inventory control.”

“Their dedicated team efforts and innovative solutions backed by thorough data analysis helped us deliver our operational targets.”

“Over the past few years, they have made significant contributions to our company’s growth and success by formulating KPIs and driving overall process improvement initiatives. They played a pivotal role in our OTIF project, which focused on improving our delivery performance and customer satisfaction.”

“We have seen significant improvement in our distribution centre with the redesign of the operations and changes in the information system, supported by Gemba Concepts during the development of the warehouse management system.”

“Gemba Concepts delivered professional and impactful services that significantly enhanced our ground-level processes and helped us identify actionable opportunities for improvement.Thanks to their involvement, we were able to streamline workflows, reduce waste, and enhance employee involvement in problem-solving.”

“Their hands-on approach and commitment to achieving measurable results have made a significant impact on our operational efficiency.”

“Gemba Concepts demonstrated a deep understanding on lean manufacturing principles and had applied them to drive improvements in our operational efficiency and productivity.”

“Their outstanding performance during this phase exceeded our expectations, leading us to extend their project for an additional four months to address other critical areas.”

“Gemba Concepts played a very significant role in not only improving the productivity of our company, but also the production team and our resources.They helped us implement OEE, improve quality, and define KPIs for strategic decision-making, leading to increased productivity and better performance.”

“The Gemba Concepts Private Limited Team demonstrated a profound and intrinsic understanding of our unique operational challenges, and their proposed solutions were not only pragmatic and effectively implemented but also strategically aligned with our long-term objectives for quality and efficiency. The tangible improvements we have observed are a direct testament to their expertise and professional diligence.”

“Gemba Concepts Pvt. Ltd. consistently exceeded our expectations, showcasing their expertise in data management and visualization, order fulfillment (OTIF), inventory management and operations review systems. Their professionalism, analytical approach, and strong commitment make them a valuable partner for any organization aiming to elevate operational and supply chain excellence.”

“Gemba Concepts Pvt. Ltd. has demonstrated exceptional capability and professionalism, consistently delivering high-impact results in Human Productivity Improvement and Inventory Carrying Cost Optimization. Their data-driven approach, strong cross-functional coordination, and deep commitment to operational excellence make them an asset to any organization.”

“Gemba Concepts Pvt. Ltd. approached each improvement area with a structured methodology and ensured alignment with our organizational goals. Throughout the project, their team demonstrated strong domain knowledge, professionalism and adaptability, ensuring smooth execution and long-term value creation.”

“Throughout the engagement, Gemba Concepts demonstrated an expertise in implementing Lean methodologies for addressing operational inefficiencies. Their professionalism, analytical approach, and commitment to continuous improvement were found satisfactory in every stage of the project.”

“Over the course of our four-month collaboration, the Gemba team consistently demonstrated professionalism, technical depth, and a results-oriented mindset. Their analytical thinking, methodical execution, and commitment to continuous improvement reflect a culture of excellence that aligns strongly with our own values.”

“The Gemba team consistently exhibited exceptional professionalism, deep technical expertise and a steadfast results-orientation. We wholeheartedly recommend Gemba Concepts Private Limited to any company seeking reliable, innovative, and results-driven solutions.”

See What’s Possible for Your Business

Talk To Us About Your Challenges

Is Your Warehouse Ready for the Next Level?

With the right strategy, your warehouse stops being a cost center. The difference is not just technology — it’s Execution, visibility through a strong warehouse management and a partner who understands operational reality. At Gemba Concepts, we combine global expertise with hands-on implementation to deliver results that show up on your floor, in your numbers and in your customer experience.

Get in Touch

Change Starts With a Conversation

Schedule Meeting Today

Fill out the form, and let’s talk about how we can support your business.

Call us at:

+91 96064 75131

For any inquires

sales@gembaconcepts.com

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