They didn’t believe we could get it done and let alone get it done in 10 weeks. But look at us now, project complete, on time, eating pizza!
THE STORY
A leading fishing tackle manufacturing company sought to improve on-time delivery by addressing sub-optimal Warehouse Management (WM) configuration and processes. The transformation goal was to optimize warehouse operations as part of a plan to ensure readiness for the move to SAP Extended Warehouse Management (EWM). This required reorganizing inventory positioning, improving pick and put-away strategies and educating teams on how to use SAP more effectively. The company engaged Reveal to help meet these objectives as well as enable system-driven efficiency tools for Capacity Planning, identifying excess and obsolete inventory, optimized Master Data, and utilize exception monitoring as a daily practice. The transformational work resulted in decreased processing times, improved customer service levels, and a reduction in manual processes that positively impacted employee morale and productivity.
THE CHALLANGE
The Warehouse transitioned from a legacy system into SAP WM. Functionality, configuration, and usage challenges resulted in unnecessary customizations, planning and operating in spreadsheets, and excessive manual processes. This was limiting the ability to automate processes and work with trustworthy data for real-time decision-making.
THE SOLUTION
Partnering with Reveal the company optimized their WM set-up, master data and supporting processes. This resulted in reducing manual work, leveraging standard SAP functions, and enabling exception-based management. Included in this optimization was using storage locations and storage types to streamline inbound and outbound flows, adjusting master data to enable automation, and implemented efficient picking and put-away strategies. User training ensured staff could effectively utilize the improved system and new processes. The project also charted a course towards future utilization of S/4HANA EWM and also uncovered additional further efficiency opportunities.
THE RESULTS
Order Processing Efficiency
New picking and put-away strategies slashed order processing time by 95% and streamlined material flow. Transfer order processing went from a manual 2-hour slog to a swift 6-minute operation.
Service Level Improvements
Warehouse activity monitor identified and resolved bottlenecks, reducing critical delivery delays by 43%. Plans are underway to address remaining issues and ensure continued improvement.
Boost in Warehouse Capacity
Capacity Management improved warehouse capacity by 16%, giving better visibility to optimize storage for high-demand items and streamline picking/put-away.
Warehouse Overhaul
Automated transfers replaced manual bin-to-bin movements, while optimized storage with new locations boosted both accountability and inventory tracking.
ABOUT
A leading global fishing tackle provider of the worlds most trusted fishing brands manufacturing and selling tackle boxes, rods, reels, and lures. With a passion for the fishing community focused on meeting the needs of modern anglers.
