Through targeted warehouse optimization, uncover hidden cost drivers – with strategy and foresight
Do you actually know whether you are fully exploiting the potential of your logistics infrastructure? Do you know your saving opportunities that can be achieved within your existing warehouse capacities?
Warehouse optimization encompasses all measures aimed at improving processes, utilization and organization within the warehouse – for example through the restructuring of shelving, automation or process improvements. The goal is to make operations more efficient, reduce costs and increase the performance of the logistics system. Modern methods, data-based tools and simulation-supported procedures play a central role in this.
Recognize improvement potential and successfully implement it
Reduction of throughput times and increase in warehouse productivity
Increase in picking performance and improvement of effectiveness
Avoidance of waste
Optimal and future-proof design of your intralogistics
Knowledge transfer and expertise from numerous logistics projects
Holistic logistics and warehouse optimization refers to the systematic analysis and improvement of logistics processes along the entire supply chain. The aim is to develop strategies that best match the specific requirements of a logistics system. In this context, the following process steps are typically involved:
By creating heat maps for the entire supply chain or individual warehouse areas, cost drivers can easily be identified.
The optimization of slot allocation is based on the article structure as well as existing storage restrictions, such as co-storage prohibitions. By systematically analyzing these parameters, efficient and compliant placement of goods in the warehouse can be achieved.
Long walking distances have a negative impact on the efficiency of picking processes. By applying suitable picking strategies and methods such as ABC analysis or shopping basket analysis, travel distances can be reduced and process speed increased.
Simulations are used in warehouse planning to evaluate material flows, capacities and technical systems. Based on historical data or defined scenarios, forecasts for the development of the logistics system can be created to support planning and decision-making processes.
Did you know? Around 50% of logistics costs arise from intralogistics—half of which from picking. This means internal material flow is a major cost driver in optimization initiatives. When warehouse processes are not closely aligned, this quickly becomes a significant cost factor for companies. In times of same-day delivery and multi-channel logistics, customers value speed, quality and efficiency. Targeted warehouse optimization helps reveal potential in internal material flow. Save time and costs—and prevent your logistics from becoming a competitive disadvantage.
Eliminating paper-based picking and switching to digital processes can significantly increase picking efficiency. By using mobile data collection devices, all order-relevant information is available digitally, removing the need for printed picking lists. This leads to faster processes and greater flexibility among staff.
Another approach to process optimization is the use of multi-order picking. In this method, several customer orders are combined into a single picking run. This reduces walking distances and increases throughput—without placing additional strain on employees.
To reduce picking errors, software-based systems are increasingly being used. Voice-guided solutions and integrated logistics software support employees in error-free order processing and provide additional analysis capabilities, such as for resource planning. These systems help increase process reliability and quality in the warehouse.
A typical procedure in optimization projects includes recording and analyzing logistics processes, creating a potential analysis, and developing an action plan. These steps help systematically identify improvement potential and derive structured recommendations for further development of the logistics system.
This whitepaper provides an overview of the current state of picking systems primarily used in e-commerce. Special attention is given to how these systems can be optimally and efficiently utilized.
Distribution time savings: approx. 10% (approx. 650 hrs/year)
Process time savings: approx. 8% (approx. 500 hrs/year)
Productivity increase: approx. 12% (approx. 350 hrs/year)
Total time savings: approx. 1,500 hrs/year
Hourly wage: approx. €18.00
Cost savings: approx. €27,000/year
Reduction of forklift vehicles: approx. 2.6 vehicles/day
Reduction of employees: approx. 5.6 employees
Revenue from vehicle sales: approx. €25,000
Labor cost savings: approx. €150,000/year
Cost savings in the 1st year: approx. €175,000
Cost savings from the 2nd year onward: approx. €150,000
Increase in technical performance: approx. 10–20%
Increase in storage capacity: approx. 25%
Reduction of empty-pallet handling: approx. 30%
Reduction in downtime: approx. 50%
Implementation within the planned project timeline
Return on investment (ROI) within the expected timeframe
Your questions about logistics and warehouse optimization.
As part of warehouse optimization, the optimal use of existing infrastructure is reviewed. This includes an actual-state analysis of processes, material flows and warehouse infrastructure, verifying optimal storage and distribution of items, and developing a warehouse optimization concept. The goal is to identify cost drivers, optimize processes and material flows, revise slot allocation and reduce travel distances.
With strategically designed warehouse optimization, you can quickly uncover hidden cost drivers. Nearly 50% of logistics costs arise from intralogistics—and half of that from picking. By reducing travel distances and intelligently distributing items in the warehouse, companies save time and money. Additional savings can be achieved in goods receiving and goods dispatch.
To identify cost drivers, modern methods and tools are used. For a holistic perspective, heat maps are created for companies—depending on requirements, for individual warehouse areas or the entire logistics chain. This immediately reveals optimization needs. Other methods include ABC analysis or shopping basket analysis. Especially in e-commerce, where every second counts in order assembly, these methods have proven effective.
Picking is the most cost-intensive factor in intralogistics and thus the core of warehouse optimization. The goal is to work as efficiently, quickly and reliably as possible. How companies can make their picking processes future-proof is outlined in our whitepaper: Four steps to successful picking.
The advantages of a holistic and strategic view of logistics are clear: You immediately identify improvement potential, reduce throughput times, increase productivity and effectiveness in the warehouse, save costs—and ensure customer satisfaction. Trust in a company’s performance is a decisive competitive advantage in the logistics market. Savings after optimization and implementation typically range between €50,000 and €100,000 per year.
The optimization of a warehouse is most successful with experts at your side. Neutral and technology-independent consulting helps address individual needs. Optimization can also be carried out during live operation, ensuring that business processes are not interrupted. In addition, consulting suites enable companies to perform independent optimizations.
Logistics consultants begin with a detailed actual-state analysis to uncover optimization potentials in the warehouse and throughout the logistics chain. The focus is on identifying root causes to ensure successful long-term implementation of measures. With knowledge and experience from numerous successful projects, specialized consulting partners are often the first choice for companies seeking to improve their logistics.
Do you have any questions? We are happy to assist you! If you would like to learn more about our holistic and manufacturer-independent warehouse planning, feel free to reach out to us! Our logistics experts are here to help you.