Warehouse & Logistics Consulting

Process Improvement & Cost Reduction

Every warehouse has a rate it's theoretically capable of, and an actual rate it runs at — the gap between the two is where cost hides. This service focuses specifically on closing that gap: pick and pack rates, pick path efficiency, and reducing indirect time that doesn't move product.

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What's Included

What's included in process improvement & cost reduction

Rate analysis

Benchmarking current pick, pack, and processing rates against what the operation is actually capable of.

Pick path optimization

Redesigning pick paths and slotting logic to cut travel time and increase units picked per hour.

Indirect time reduction

Identifying and reducing time spent on non-productive tasks: walking, waiting, searching, rework.

Cost-per-unit modeling

Connecting rate improvements directly to cost per unit processed, so gains are measurable in dollars, not just percentages.

Our Approach

How we approach it

Time studies — measure current rates and indirect time across key tasks.
Root cause analysis — identify where time and cost are actually being lost.
Redesign — optimize pick paths, task sequencing, and labor standards.
Implementation — roll out changes with the team, track rate and cost-per-unit impact.

Is This For You

Signs you need this

Pick/pack rates have plateaued despite process changes.
Cost per unit is rising even as volume grows.
You suspect time is going to walking, searching, or waiting, but don't have hard numbers.
You're benchmarking against a network or industry standard and falling short.

Let's talk about process improvement & cost reduction for your operation.

Reach out for a consultation — we serve warehouses and distribution centers across Canada and the United States.

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FAQ

Common questions about process improvement & cost reduction

What's the difference between this and Workflow Design & SOPs?

Workflow Design & SOPs is about how a process is designed and documented. Process Improvement & Cost Reduction is about the numbers — rate and pick path — making sure the design actually performs at the rate and cost it should.

Do you use time studies?

Yes. Direct observation and time studies are typically the starting point, so recommendations are based on your actual operation, not a generic benchmark.

How is this measured?

Primarily through units-per-hour rate and cost per unit, tracked before and after changes.