Bazaar Kolkata
Project Overview
Currently, BRL serves its 120 in-house stores. Driven by a vision to establish a strong physical presence across the Eastern Region of India, BRL plans to expand its reach to 200+ stores by 2026 in West Bengal, Uttar Pradesh, Bihar, Jharkhand, Tripura, Assam, and Odisha from its 1,57,000 sq. ft. central distribution centre.


Business Challenges
- Design a central warehouse that accommodates over 400,000 pieces of fresh inventory every day.
- Develop the ideal strategies for put-away, storage, picking, and sorting to handle SKUs.
- Establish the optimal mix of manual labour, mechanisation, and automation.
- Ensure seamless man-material-equipment flow, foster healthy working conditions, and ensure scalability.

Our Solutions
- Factored scalability into the storage system design to optimally accommodate more than 40 lakh pieces of inventory per day.
- Designed unilateral flow for man and material.
- Maximised cube storage capacity with column-supported mezzanines and multi-tier shelving systems, incorporating standard storage bins and meiser gratings catwalks to improve aisle ventilation and facilitate the use of hand pallet trucks.
- Integrated automation to reduce manual intervention and increase the capacity to serve more stores through:
- Handheld Terminals for Picking: Reduced operator strain and fatigue.
- Lifts and Motorised Inclined Conveyors: Enabled seamless vertical movement of SKUs for inbound and outbound operations, improving order processing speeds.
- Dynamic Sorting Operations: Destination-wise automated sorting using swivel wheel sorters, boosting sorting productivity.
- Aligned physical processes and the Warehouse Management System (WMS) seamlessly.
- Enhanced workforce efficiency with ergonomically designed checking and packing stations, optimised LUX levels, and stringent surveillance across all operational levels.
- Strategically segregated and aligned inward and outward processing stations across multiple levels to streamline workflows.

Coign’s Impact
- The CDC efficiently manages over 8,500 outbound cartons/day.
- Scaled operations to serve 200+ stores.
- Ensured precise and complete order-wise picking and packing.
- Facilitated timely dispatches and deliveries.
- Increased process transparency and visibility.
