Grace Supermarket

Project Overview

Grace Supermarket is the largest supermarket chain in Chennai, known for offering the freshest products at affordable prices. Currently serving 36 retail outlets in Chennai, Grace Supermarket is set to expand to 84 outlets across Tamil Nadu by 2028, with operations supported by their new 75,000 Sq.ft. distribution centre in Chennai.

Business Challenges

Streamline the bi-directional movement and mixing of inbound and outbound materials.
Develop efficient picking, sorting, consolidation, and dispatch methods to pace order fulfilment.
Identify the optimal mix of human efforts, mechanisation, and automation.
Redesign the layout to improve throughput and productivity by optimising material flow.

Our Solutions

Segregated inbound and outbound docks based on receipt and dispatch timings for warehousing and sortation operations.
Introduced categorisation of received SKU cartons based on the packing SOP after offloading.
For sortation operations:
- Designed dynamic G+1 put-to-light operations for each category, with 84 unique store locations.
- Equipped each store location with a returnable plastic tote, colour-coded by category.
- Integrated G+1 PTL racks with a motorised conveyor to automatically segregate totes by store (84 sorters).
- Streamlined and automated processes to enhance sorting and dispatch operations.
Recommended a resource requirement and utilisation matrix for efficient warehouse operations.
Optimised cube storage by implementing tall shelving systems for inventory storage.
Designed a unilateral flow of man and material.
Integrated physical processes with WMS seamlessly .
Planned estate roads to accommodate various vehicular types and traffic patterns.