Utilizing a decade-old system, especially in warehouse management, can lead to delays and inefficient operations. From three different steps for picking, segregation, and packaging to a lack of effective picklists, sales-returns segregation, and order prioritization obstructed the workflow
However, Prismberry acted as a strategic partner to help the company streamline the processes, digitizing the picking, and optimizing the logistics. Let’s understand how Prismberry’s solutions revolutionized the old system, making it more efficient and easy to process.
Annual Savings Delivered
Solutions Delivered
Satisfied Customers
Increase in Energy Efficiency
Many operational challenges impede efficiency and customer satisfaction. Let’s look at the following major issues due to the outdated Warehouse Management System (WMS).
System Load Failure
As the load increased, the system failed, which affected the smooth functioning.
Manpower and Time Overhead
The workflow was burdened with high manpower consumption and time overheads that affected overall productivity.
Inefficient Shelf Visits
Pickers were forced to revisit the same shelf several times for one pick list, which resulted in a waste of time and energy.
Configuration Limitations
The lack of a picklist configuration made it impossible for trolleys to handle OTC and Medicinal products at the same time.
Shipment Acceptance Dilemma
The system’s binary approach to approving or rejecting the whole shipment affected the operations in terms of financial losses and customer relationships
Order Processing Inconsistency
The absence of order prioritization led to processing orders only according to the date when they were placed, which caused operational inconsistencies.
Paper Cost and Wastage
Manual processes resulted in additional paper costs, wastage, and pickers’ time.
Order Misclassification
Customers placed a combined order containing OTC and Medicine, but processing considered them as separate orders, and this confusion persisted till the end.
Here’s how Prismberry tackled each challenge with innovative strategies
01. Merged Picking and Segregation Processes
Introduced tray along with trolley carts that integrated picking and segregation.
03. Segregation and Packing Consolidation
Streamlined the process further by merging segregation and packing screens.
05. Shelf-Based Picking Optimization
The Sort by ShelfNo. feature was introduced, which allowed the pickers to collect all goods from one shelf in an economical manner.
07. Configurable Picklists
Applied picklist configuration so that trolleys could carry out OTC and Medicinal products at the same time
02. Return Segregation Implementation
Implemented return segregation, with packaging details and quantities captured in returns processing for better efficiency
04. Order Prioritization with Cutoff Date
Introduced CutoffDate for orders feature, where picking was done by placement date to ensure consistent processing
06. Digitalized Picking with HHD
HHD digitized picking, replacing manual processes, leading to greater accuracy
08. OTC and Medicine Order Merging
Merged OTC and Medicine orders under a parent order that simplified the post-picking process of streamlined order management.
01. Merged Picking and Segregation Processes
Introduced tray along with trolley carts that integrated picking and segregation.
02. Return Segregation Implementation
Implemented return segregation, with packaging details and quantities captured in returns processing for better efficiency
03. Segregation and Packing Consolidation
Streamlined the process further by merging segregation and packing screens.
04. Order Prioritization with Cutoff Date
Introduced CutoffDate for orders feature, where picking was done by placement date to ensure consistent processing
05. Shelf-Based Picking Optimization
The Sort by ShelfNo. feature was introduced, which allowed the pickers to collect all goods from one shelf in an economical manner.
06. Digitalized Picking with HHD
HHD digitized picking, replacing manual processes, leading to greater accuracy
07. Configurable Picklists
Applied picklist configuration so that trolleys could carry out OTC and Medicinal products at the same time
08. OTC and Medicine Order Merging
Merged OTC and Medicine orders under a parent order that simplified the post-picking process of streamlined order management.
Results
The effectiveness of the solutions offered by Prismberry improved warehouse management, which can be regarded as a drastic change in terms of efficiency and cost savings.
The system can smoothly process 35,000-50,00 orders a day to reach and cater to around 1.5 crore orders in the year 2023
orders in the year 2023
The system can process over 1 lakh orders per day, a significant improvement in processing capacity
orders per day
Operational steps were reduced from 3 to 2, reducing the workforce requirement by two-thirds and total processing time by three-fifths
manpower reduced
Significant saving of pickers’ time with improved picking operations
of picker’s time
Trolleys can now process orders of any type, resulting in high flexibility and maximized resource utilization
and maximized resource utilization
The precise documentation of the quantities to level returns allowed to retrieve around 50-60 lakhs INR every month.
cost optimization
The solution led to a 1.2% gain in speed and reduced the breaches from 0.8% to 0.1%.
enhanced the operational speed
The earlier capacity, which was 1.25x, was reduced to an effective 1.1x
reduced capacity
The cost optimization of paper was ensured by up to 60%, resulting in saved picker time and savings of Rs. 1 per invoice.
cost optimization
The economic benefits of around Rs.25 lakhs of monthly savings were ensured, and a 30% reduction in additional shipments compared to the previous scenario.
monthly savings
