Warehouse Operations Case Study

Streamlining Warehouse Operations for a Leading Indian Airline in Bengaluru

A leading Indian airline faced challenges with its Bengaluru warehouse, a critical hub handling multi-tonne daily volumes of essential in-flight products. Operational inefficiencies, including slow order fulfillment, inaccurate inventory tracking, and poor space utilization, were impacting business and customer satisfaction.

Challenges Faced by the Client

  • Improve order picking accuracy and speed, minimize errors, and ensure timely delivery to aircraft. Streamline multi-tonne volume per day of various daily operations products.

  • Gain real-time visibility into stock levels, reduce stockouts, and minimize inventory holding costs.

  • Maximize warehouse capacity to accommodate growing operational demands.

  • Achieve smooth transition with minimal disruption to daily flight operations during the operational takeover.

Results Achieved

Reduced order picking errors by 15% and shortened order fulfillment times by 20%.

Reduced stockouts by 10% and minimized inventory holding costs.

Increased warehouse capacity by 15% through optimized storage and efficient use of available space.

Achieved smooth transition with minimal disruption to flight operations during the takeover.

Reduced labour costs and improved overall warehouse productivity.

A comprehensive warehouse operations management plan was implemented within a three-week timeframe

  • 1. Rapid Assessment: A thorough assessment of existing processes, infrastructure, and technology was conducted. Key pain points were identified, including manual processes, outdated technology, and inefficient layout.
  • 2. Process Re-engineering: Lean principles were applied to streamline order picking, packing, and shipping processes. A new workflow was designed to optimize labour utilization and minimize travel distances within the warehouse.
  • 3. Staff Training & Development: Comprehensive training programs were conducted to equip warehouse staff with the necessary skills to operate the new systems and processes effectively.
  • 4. Continuous Improvement: A robust monitoring and feedback system was established to track key performance indicators (KPIs) and identify areas for continuous improvement.

Conclusion

This case study demonstrates the successful implementation of a comprehensive warehouse operations management plan for a leading Indian airline. By leveraging technology, streamlining processes, and focusing on continuous improvement, the airline achieved significant improvements in operational efficiency, customer satisfaction, and bottom-line results. This project serves as a model for other organizations seeking to optimize their warehouse operations and enhance their supply chain performance.

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