Warehouse Management System (WMS)
We implement smart, cloud-based WMS solutions that enhance inventory visibility, streamline dispatches, and optimize space utilization.
99.9%
Achieve
Inventory Precision
60%
Dispatch
Lead-Time Reduction
Track Records
100%
Tailor Made Solution
2CR+
Sqft Warehouse Design
12+
Years of Experience
Real World Impact
Results That Drive Transformation
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%
Call Us Today to Schedule a Free Consultation
Key Services
01
Warehouse Layout & Infrastructure
Design & Visualization
With 2D/3D visuals for optimal space planning and workflow efficiency.
02
Inventory Optimization
Analysis & Strategy
Via ABC analysis and strategic slotting for maximum inventory control.
03
WMS Framework Development
Custom Solutions
Requirements, wireframes, and validation for customized warehouse management.
04
MHE & Racking Ecosystem
Selection & Implementation
Strategic selection for optimal space utilization and material flow.
05
Manpower Planning
Optimization & Management
With standards, KPIs, and organograms for workforce optimization.
Proven Results in Chemical Home Appliance Packaging Retail FMCG Industry
Case Study
How a Chemical Manufacturer Achieved 25% Faster Lead Times & 30% WIP Reduction
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: Spaghetti Diagram— Gemba— Time & Motion Study— Bottleneck— Product Family
- Design: Pull System— Drum-Buffer-Rope (DBR)— Bucket Filling— Single Batch Flow Reallocation
- Sustain: Kaizen— Routine Maintenance Planning
The Challenge
- High Work In Progress (WIP)
- Long & Unpredictable Manufacturing Lead Time
- Low Reactor Utilization
- Recurring Bottleneck
- Reactive Maintenance Downtime
- Fragmented Production Planning
Business Impact
- More predictability.
- Less firefighting.
- Stronger cash flow.
The Results
25%
30%
85%
25%
Lead Time Reduction
Higher Reactor Utilization
On-Time Delivery
Lower WIP
Case Study
How a Home Appliances Manufacturer Improved Productivity by 50% & Reduced Lead Time by 90%
The Challenge
- Inefficient shopfloor layout
- High manual handling and excess movement
- Non-standardized post-molding activities
- Low manpower productivity
- Lack of standard processes
- Dependency on people instead of systems
What We Changed
- Analyze: Entire Process Flow Mapping — Gemba Walks — Time & Motion Study — Bottleneck Identification — Material Flow Analysis
- Design: Lean Layout — Single Piece Flow — Line Balancing — Multi-Manning — Packing Process Standardization
- Sustain: SOP Preparation — Skill Matrix — Team Training — Kaizen
The Challenge
- Inefficient shopfloor layout
- High manual handling and excess movement
- Non-standardized post-molding activities
- Low manpower productivity
- Lack of standard processes
- Dependency on people instead of systems
Business Impact
- Lower operating costs.
- Higher throughput with the same manpower.
- More stable and predictable operations.
- Reduced dependency on individuals.
The Results
20%
50%
90%
Manpower Cost Reduction
Productivity Improvement
Reduction in Lead Time
Case Study
How a Packaging Manufacturer Reduced Changeover Time by 30% & Improved Per-Shift Output by 20%
The Challenge
- Long and inefficient printing job changeovers
- High material wastage impacting profitability
- Low per-shift productivity in slitting & lamination
- Presence of Non-Value-Adding (NVA) activities
- Lack of standardized shopfloor practices
- Limited visibility of performance KPIs
What We Changed
- Analyze: As-is Process Mapping — Gap Analysis — Time & Motion Study — NVA Identification — Gemba Walks
- Design: SMED Implementation — 5S — Production Planning Optimization — Bottleneck Removal — Reuse of Rejected Materials for Job Setting
- Sustain: OPL & Team Training — Rewards & Recognition (R&R) Scheme — KPI Dashboards — Defined KRAs & Structured Handover
The Challenge
- Long and inefficient printing job changeovers
- High material wastage impacting profitability
- Low per-shift productivity in slitting & lamination
- Presence of Non-Value-Adding (NVA) activities
- Lack of standardized shopfloor practices
- Limited visibility of performance KPIs
Business Impact
- Faster changeovers and improved asset utilization.
- Reduced wastage and direct cost savings.
- Higher per-shift productivity.
- More disciplined and standardized shopfloor operations.
- Stronger process ownership and sustainability.
The Results
85 Lakhs
Savings from Wastage Reduction
Savings from Wastage Reduction
30%
20%
Reduction in Printing Job Changeover Time
Improvement in Lamination & Slitting Output per Shift
Case Study
How a Footwear Ecommerce Distribution Centre Cut Manpower by 22% While Increasing Orders per Person by 24%
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: Spaghetti — Time/Motion — Inventory/Capacity — Bottlenecks — Line Balancing
- Design: In/out flow optimization — Lean layout — Conveyors — Manpower planning — POC validation
- Sustain: Infra build — Poka Yoke — WMS inventory — Standardized lean workflows
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
Business Impact
- Higher operational efficiency at scale.
- Reduced dependency on manpower.
- Faster order fulfilment with fewer errors.
- Improved inventory visibility and control.
- Lean, scalable ecommerce distribution setup.
The Results
Inventory Mapping and Optimization through WMS
Lean Layout Design
22%
35%
20%
24%
Manpower Reduction
Improvement in Throughput Time
Improvement in Orders per Person
Reduction in Repacking Cost
Case Study
How This FMCG Manufacturer Cut PM Inventory Costs by 60% and Raised Productivity by 22%—Without Expansion
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
Lean-driven FMCG Transformation using:
ABC Analysis, Just-In-Time (JIT), Line Balancing, Kanban, SMED, 5S, Kaizen, Bottleneck Analysis, Time & Motion Study, and Digitized Process Controls.
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
Business Impact
- Lower working capital locked in inventory.
- Higher shop-floor productivity.
- Improved planning accuracy and dispatch reliability.
- Scalable operations through optimized layout design.
The Results
Optimized Layout
Enabled Installation of Additional Production Lines
22%
60%
99.5%
Productivity Improvement
PM Inventory Cost Reduction
On-Time In-Full (OTIF) Performance
Gallery
Our Clients
Why They Chose Us — & What Followed
Nandish Gulecha
Managing Director
We have seen significant improvement in our distribution center 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
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