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Rapidly growing eCommerce function for well-known high street retailer

Founded in 1872 and bought by former Dragons’ Den investor – Theo Paphitis – in 2012, Robert Dyas is a well-known high street retailer offering a wide range of products from practical kitchen essentials to innovative DIY gadgets. There are over 90 stores spread across the South of England; of which the UK based retailer offers a substantial and rapidly growing eCommerce function, comprising a click & collect service.

Robert Dyas had been experiencing a period of fast paced growth and needed to update warehouse management processes to reflect this and avoid their distribution centre reaching capacity limit.
To facilitate business growth continuing at a fast pace, and increase productivity focused on the eCommerce operation, the management team concluded a review was required, to identify any changes to layout and processes that would improve facility productivity and efficiency.

After an extensive selection process, our experienced Logistics and Supply Chain Consultants were enlisted to undertake this review, due to our knowledge, specific skill set, and expertise.
The team of Specialist Logistics and Supply Chain Consultants conducted a review using data analysis of performance reports, data analysis of throughput data, and observations of the operation. They split the review into three stages; Data Acquisition, E-commerce Area Layout Design, and Main Warehouse Layout & Process Review.

The data analysis team applied standard methodology for reviewing pick-face sizing and SKU allocation. This analysis traded off pick-face density against frequency of replenishment to determine the most productive mix of pick-face sizes. Considering seasonality of product sales, and the annual ‘churn’ in the SKU range was important in determining the number of locations required and defining seasonal picking areas and dynamic pick faces.

At each stage in the analysis, the findings were reviewed with the client’s operational management team in workshop sessions. The main issues identified by the consultants concerned the need to improve upon: storage locations and access space for cage marshalling, pick face sizing; KPI reporting, and SKU location.

Having defined the constitution of the picking area, our warehouse layout design consultants provided detailed layout options with CAD drawings and capital cost schedules. Improved warehouse layouts were proposed, that increased clear area for marshalling and re-use, and a reshaped cage marshalling area; prior to providing their final set of recommendations which were suitable to the specific requirements of the Robert Dyas team.