Performance Results for a 1.25M Sq. Ft. Automotive Warehouse
The results were so great we were awarded the 2023 Supply Chain Partner of the year from the customer.
48%
increase in units processed per shift
98%
order accuracy and significantly improved order fulfillment speed
36%
reduction in headcount
55%
year-over-year workforce turnover reduction
Customer Profile
When a major Japanese automotive manufacturer needed help managing a 1.25 million sq. ft. warehouse facility adjacent to its car assembly plant, they turned to Capstone Logistics.
The Challenge
- High turnover and unstable warehouse workforce
- Daily builds and warehouse backlogs led
- Frequent production line interruptions
- Increased costs for warehouse labor
- The reliance on temp labor exacerbated the problems
The Solution
Capstone engineers began with a detailed operations assessment including time studies and a labor cost analysis:
- Led setting up of common KPIs with other 3PLs on site
- Deployed a travel team to stabilize operations and smooth the transition to a long-term solution
- Data-driven insights for visibility and real-time reporting solution
Once the assessment was reviewed and approved, we put together full-service solutions to meet the customer’s needs.
- Inbound services: scheduling, receiving, unloading, and put-away
- Outbound services: picking and packing, and loading
- Manufacturing support: kitting, light assembly, packing
- Value-added services: driver support, sanitation and auxiliary services, security and yard management