Accelerating logistics flows in a complex assembly environment
A leading automotive manufacturer with a European assembly plant was preparing for a major logistical transformation to support the launch of a newly allocated car model. Central to the challenge was the need to design efficient inbound logistics flows and a fit-for-purpose warehouse setup for thousands of parts feeding the assembly line. Although the project initially faced alignment challenges, it sparked stronger cross-functional collaboration and led to the development of a more structured approach for managing complex, large-scale transformations - setting the stage for smoother execution going forward.
Ambition: Streamlined logistics for future-ready operations
In the master planning phase, the objective was to seamlessly integrate the new car model into existing operations. The focus lay on designing optimal logistics flows and a future-proof warehouse setup for parts. This phase also established the foundation for structured decision-making and enabled logistics engineering through robust analysis, standardized templates, and proven methods.
How we helped: Precision in planning and execution
The warehouse master planning phase was driven by a thorough product and volume analysis, material flow definition, and high-level shopfloor layout design. Project coordination was facilitated through regular engineering meetings and meticulous documentation of progress. Logistics engineering was supported by clear analysis, standardized templates, and proven methods - enabling structured decision-making throughout the process.
Results: Master plan for optimized logistics center and enhanced capacity
A detailed capacity and volume analysis determined the square meter and full-time equivalent (FTE) needs for the new logistics setup. The design and validation of the logistics layout ensured that the future warehouse would operate efficiently and effectively. Comprehensive cost calculations were conducted to support the warehouse capital expenditure (CAPEX) and the financial business case. Finally, a detailed facility deployment plan was delivered, ensuring a smooth transition to the new logistics setup.
Looking to optimize your logistics and prepare your operations for future growth? Contact us today to learn how we can help you.
