Warehousing & Fulfilment
Industry
Achieve your growth aspirations with our transformation process
The FlowPlus™ transformation process
Over 20 UK warehouses/ fulfillment centres are now reaching their full potential using our 4-step transformation process.
1. DISCOVERY
By starting with a discovery phase, we understand your unique production process and the challenges you face - uncovering areas for improvement and your gap-to-potential.
Gain all the insight in one, concise, step by step assessment report.
01
Lean Maturity Audit
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Assess your lean maturity across 25 categories including efficiency, automation, visual management, standards, process control, customer focus, product flow, leadership, culture and more.
02
Performance Analysis
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Great processes create great results, Simple but not easy.
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We review your current processes to gain an in-depth understanding of existing pain-points, where information sharing and communication breaks down & waste steps that can be eliminated/automated.
03
Gap to potential analysis
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Quantify the gap between your current state and desired state, understand what changes are needed to become best-in-class manufacturers.
04
Implementation roadmap
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Convert improvement actions into projects, and produce a bespoke improvement roadmap aligned with your company strategy.
2. ASSESSMENT
The Assessment phase investigates the unique solutions required to close your gap-to-potential and become a best-in-class warehouse or fulfilment centre. Creating a bespoke implementation roadmap aligned with your strategic aims, we provide you with a practical step by step approach needed to get tangible results fast.
05
Customer Feedback Analysis
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Using AI and advanced machine learning techniques, we will identify what your customers care most about and innovative ways of exceeding their expectations.
06
Process Mapping​
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Painting a clear picture of your warehouse and dispatch systems, you will start to see the waste and improvement opportunities that have been hidden all this time.
07
Motion tracking​
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Quantify the waste of motion & transport with the latest technology. Find optimised layouts, storage solutions, floorplans and pick routes by tracking products, people & forklifts. Increasing productivity, minimising H&S risks and improving communication.
08
Flow Analysis
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There is often huge untapped potential when improving the flow of your system. Understand how to balance work and minimise lead time with our flow analysis tool.
09
Space Utilisation Analysis
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Quantify the space utilisation of storage solutions and uncover any improvements to storage density or productivity related to stock movement.
3. IMPLEMENTATION
Implementation is what we pride ourselves on. We don't write reports and leave the hard part to you...We roll up our sleeves, get on the shopfloor and make the changes needed.
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Working with the operators that know the processes best, we conduct workshops as one-team, until the target is achieved.
The solutions we implement are tailored to each client and the unique challenges in their assessment. Examples range from re-designing and transforming a warehouse layouts to maximise storage utilisation, through to implementing new workstations, trolleys and dispatch systems to increase pack rate.
Increase in space utilisation
Improvement in operator productivity
Increase Pick & Pack
Rate
Minimise health & safety incidents
4. TRAINING
We offer both in-person & online training. Both training courses are deliberately different to other training providers in one main way, it's practical & hands-on.
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Our online training course has global recognition and has a review rating of 4.8/5 from over 7,500 active students.
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Like the in-person training, the online courses provide you with the practical ability to apply the lean tools.
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We have 5 different courses varying in complexity/commitment.
7500+
No of students we have trained globally
Topics covered in the training
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What is Lean?
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Lean Warehousing
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Best-in-class warehousing case studies
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​Introduction to Six Sigma
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Identifying and Eliminating Waste
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History of Lean​
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Kaizen​ (Yellow)
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Change management & Paradigms
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Flow, Batch Sizes, Push vs Pull & Takt
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Visual Management​
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Line Layout & design
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Supermarkets
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Hoshin Kanri
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Spaghetti Diagrams
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Value Stream Mapping (VSM)
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Overall Equipment Effectiveness (OEE)
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Standards & Standard Work
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Total Productive Maintenance (TPM)
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Quick Changeovers (SMED)
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5s - Productive Workspaces
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Collaborative Problem Solving, A3, 5Whys, Fishbone, Root Cause Analysis (RCA)
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The DMAIC Process
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Advanced DMAIC process​
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Taguchi Loss Function​
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Statistical Process Control
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Kano Model​
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Quality Function Deployment​
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Training within Industry
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Logistics trains
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Voice of the customer
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Process Mapping
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Standard work
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Work Balancing
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Heijunka
CASE STUDIES
A selection of success stories.
Warehouse
Redesigned storage solution
Increased storage utilisation by 60%
E-commerce Despatch
Implemented WMS system & flow racking
Reduced errors by 80%
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Despatch capacity increased from 1400 / day to 4000 / day
Fulfilment Centre
Installed new workstations and pick trolleys
Increased pack rate by 300%
Increased pick rate by 80%
Fulfilment Centre
Introduced storage and pick route strategy
Reduced pick route distance by 75%.
TESTIMONIALS
Our company grew considerably during the Covid pandemic and our dispatch department became our bottleneck. FlowPlus helped us triple our daily output capacity in under a year.
Josh Bassett -
Fulfilment Manager
The challenges we faced in our warehouse were quite unique and FlowPlus were brilliant in designing bespoke solutions with our team to combat our challenges. They worked with us throughout the implementation including a late night installing new flow racks, and their input went a long way, even making adjustments during installation to ensure everything exactly suited our needs.
Walter Barnes -
Warehouse Manager
As a fulfilment warehouse we didn't see the applicability of lean six sigma, however after doing the free assessment provided by FlowPlus we saw how many improvements we could make.
Andrew Hutton -
COO