CASE STUDY: DISTRIBUTION
Design Thinking
Value Creation Workshop
A Global CPG Manufacturer Increased Throughput and Reduced Labor Needs
Our customer was facing a volatile and rapidly changing consumer demand market, rising labor costs, and space constraints.
CHALLENGE
Overcoming
Operational Complexity to Scale Efficiently
Our customer’s distribution operation spanned over 1 million sq. ft., handling omnichannel fulfillment with multiple SKU storage and handling types. They needed to increase volume throughput within six months—without expanding their footprint or increasing labor costs.
SOLUTION
See Our Solution
Harnessing Design Thinking for Scalable Innovation
We conducted a Design Thinking Value Creation Workshop that guided teams through:
Discovery & Brainstorming
Identifying pain points
and inefficiencies
Ideation & Design
Developing innovative, scalable solutions
Implementation
Prioritizing and executing top 25 opportunities
Cross-functional teams executed these solutions over six months, resulting in not only cost savings but also operational improvements, including enhanced morale, reduced training time, and greater workflow visibility.
RESULTS
Increased volume throughput within six months time in the same footprint
$
INCREASTED RETENTION
$600K Cost Reduction
Harnessing Design Thinking for Scalable Innovation
Our solution resulted in an improved product handling flow, which brought about increased employee morale and retention. They were able to realize an annual cost reduction of over $600K.
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The safety incident rate was reduced to below 2%, marking a significant enhancement in workplace safety.
Productivity surged by 66%, exceeding initial expectations.
The cost per unit (CPU) decreased by 35%, resulting in substantial savings for the CPG brand.
The reliance on temporary labor diminished by 56%, indicating improved labor efficiency and better cost control.
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