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Warehouse Process Improvement

Warehouse process improvements boost productivity, drive profitability, and enhance the customer experience. Working closely with your warehousing teams, we’ll identify, design and implement improvements to make your operations run smoother.

About our service

Improving warehouse processes

At Hatmill, our warehouse process improvement service focuses on enhancing operational efficiency and reducing costs through expert analysis and strategic optimisation. 

We evaluate your current warehouse processes using our Operational Maturity Assessment Tool (O-MAT) to benchmark your activities and performance and provide a clear roadmap to make improvements.

Our tailored solutions include redesigning layouts, optimising inventory management, and integrating technological solutions. By partnering with us, you can expect improved productivity, faster and reliable order fulfilment, and greater overall efficiency, ensuring your warehouse operations are well-positioned to meet growing demands and drive business success.

What is warehouse process improvement?

Warehouse process improvement involves analysing and optimising warehouse operations to enhance efficiency, reduce costs, and improve productivity. This includes evaluating current workflows, identifying bottlenecks, and implementing best practices for layout design, inventory management, and automation. 

The goal is to streamline processes, minimise errors, and accelerate order fulfilment. Effective warehouse process improvement leads to better space utilisation, reduced operational costs, and improved customer satisfaction by ensuring timely and accurate deliveries.

Process & considerations

The Hatmill approach to warehouse process improvement

We have used the experience and knowledge of our team to develop our process improvement methodology. Here are the key steps:

Current state assessment

We’ll begin by conducting a thorough assessment of your existing warehouse processes. This involves analysing workflows, inventory management practices, space utilisation, and equipment efficiency. The aim is to identify areas of inefficiency and gather data for informed decision-making.

Data analysis & benchmarking

We’ll then analyse the collected data and insight and compare it against industry benchmarks to identify performance gaps. This step determines where and how big the opportunities are.

Process redesign

We’ll then work to adapt your warehouse processes to address identified inefficiencies. This can include reconfiguring the layout for better space utilisation, optimising picking and packing procedures, and streamlining workflows to reduce bottlenecks and improve throughput.

Technology integration

Often we’ll recommend technologies such as Warehouse Management Systems (WMS), automation, and data analytics. These technologies can enhance accuracy, speed up processes, and provide better support for decision making.

Training & implementation

We’ll ensure  your team is involved throughout the improvement process. We will use our change readiness assessment to guide the project on how to best engage the team and increase their skills. This delivers a competent, involved team working in a new way.

Continuous monitoring & improvement

We’ll establish a system for ongoing monitoring and continuous improvement. This ensures that the warehouse processes remain efficient and adapt to changing business needs.

“We chose Hatmill due to their reputation and proven track record in warehousing design and move management. They always took the time to engage with key stakeholders, understanding the business needs before designing their solutions.”

– Paul Roughley, Group Operations Director, CMS

Benchmarking performance

We’ll observe your current warehouse processes in action, and along with your warehouse data we’ll compare the performance of your warehouse operations against industry benchmarks so we can identify opportunities for improvements.

Improvements & implementation

We’ll make recommendations, including the expected costs and savings – we can also design and then manage the implementation of the process improvements. We’ll ensure that your staff are fully trained and that all new processes are embedded into your warehousing operations. We can also help to develop the methodology to measure performance and continued adherence to the new warehousing processes.

FAQs

What should you know?

  • Warehouse processes can be improved by optimising layout design, streamlining picking and packing procedures, integrating advanced technologies like Warehouse Management Systems (WMS) and automation, enhancing inventory management, improving space utilisation, and providing ongoing staff training. These improvements boost efficiency, reduce costs, and accelerate order fulfilment.

  • If you’re starting to use outside storage, having to delay inbound deliveries to have space to receive them, or are increasing the number of times you’re touching your products then your warehouse is too small. By visiting your site, observing how you operate, and analysing relevant data, we can help you establish the best course of action.

Case studies

Our work

From initial concept through to end of cutover, Hatmill worked to scope, project manage and deliver Greggs’ new, state-of-the-art £26m Balliol National Distribution Centre.

The facility consolidated Greggs’ legacy network of 4 external storage sites into a single, purpose-built national Distribution Centre and is estimated to save 7% of total mileage a year in transport emissions.

Read More about Greggs Balliol National Distribution Centre

Automation

Greggs Balliol National Distribution Centre

Greggs’ state-of-the-art automated DC – a 32m high, 40,000 sq. ft. hypoxic automated freezer extension – thaws out frozen storage capacity issues.

""Throughout our time working with Hatmill, I have remained impressed with the organisation, focus and tenacity of the team, and they have been instrumental in helping our organisation reach some critical decision points. The team are engaging, personable and a pleasure to work with, and operate seamlessly alongside Greggs colleagues"." - Phil Wright, Head of Logistics, Greggs

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