Al Abdul Karim – International Clients
AL Abdul Karim Project Overview Al Abdul Karim & Co. is a leading retail company in the Middle East renowned for offering globally recognised brands. Currently operating 141 stores under its in-house brands across Saudi Arabia, the company aims to expand its footprint to over 300 stores by 2027. This growth will be supported by its central distribution centre in Kaden, Riyadh, which spans 5,400 square metres. Business Challenges Establish a central distribution centre capable of handling over 600,000 fresh inventory daily across all brands. Identify the ideal put-away, storage, picking, and sorting pedagogy for B2B and B2C operations. Determine the optimal blend of human effort, mechanisation, and automation. Ensure smooth man-material-equipment flow, foster healthy working conditions, and support scalability. Our Solutions Designed unidirectional flow for both personnel and materials. Optimised tall pallet racking storage by minimising aisle space using articulated forklifts. Enhanced cube storage with column-supported mezzanines and multi-tier shelving systems, incorporating standard storage bins and Meiser gratings catwalks for better air circulation and efficient use of hand pallet trucks. Increased store service capacity while reducing human intervention through automation. Barcode readers are used during picking to reduce strain and fatigue. Lifts and separate motorised flatbed and spiral conveyors for vertical SKU movement in B2B and B2C operations, boosting order processing speed. Automated route-wise sorting of picked materials using swivel wheel sorters to increase sorting productivity. Put-to-light systems for store-wise sorting, ensuring accurate packing. Lightweight packing slip handheld printers for efficiency Seamless integration of physical processes and the warehouse management system (WMS). Improved productivity with ergonomic, durable operating trolleys and well-lit checking and packing stations, ensuring appropriate LUX levels and rigorous monitoring. Recommended a resource requirement and utilisation matrix to optimise warehouse operations. Coign’s Impact The CDC serviced over 12,000 pieces/ day for B2B and 2,500 pieces/ day for B2C Ensured accurate and complete order-wise picking and packing. Facilitated timely dispatch and delivery. Enhanced process transparency and visibility. Other casestudies Croma m baazar Allana Nexion Tiles The Sleep Company Grace Supermarket Borosil Load More Coign Services Used: IWD: Intra Warehouse Design VSA: Vendor Sourcing Assistance Services & Utility Design (SUD) SOP Writing Optimise your warehouse operations with our efficient designs CONNECT WITH US
Kapico – International Clients
Kapico Project Overview Kapico is a leading name in the UAE automotive aftermarket industry, serving domestic and export markets through an extensive distribution network and retail outlets. Its product ranges include high-quality replacement parts for Japanese and Korean vehicles. With a vision to expand its product portfolio, the company decided to relocate to a larger warehouse spanning 31,000 sq. ft. in Al Quasis, Dubai, to support future scalability. Business Challenges Design a central warehouse that accommodates over 400,000 pieces of fresh inventory every day. Develop efficient put-away, storage, and picking strategies for efficient SKU handling. Identify the ideal mix of manual labour, mechanisation, and automation. Ensure a seamless people, materials, and equipment flow while maintaining healthy working conditions and scalability. Our Solutions Factored storage system scalability to accommodate over 5,00,000 fresh inventory daily across all brands efficiently. Implemented unilateral flow for both people and materials. Optimised cube storage with selective pallet racking and multi-tier shelving systems, incorporating Meiser gratings catwalks to improve airflow and support efficient hand pallet truck usage. Designed flexible storage bins at the pick face to easily accommodate various SKU shapes and desired quantities of library partitions and ergonomically designed process trolleys and workstations. Infused mechanisation to reduce human intervention and increase order processing capacity, including: Barcode readers during picking to reduce strain and fatigue. Motorised spiral conveyors for vertical SKU movement, saving time and effort. Lightweight handheld packing slip printers for enhanced mobility. Achieved seamless integration of physical processes with WMS. Boosted productivity with ergonomic, durable checking and packing stations, optimal LUX levels, and stringent surveillance. Coign’s Impact The warehouse serviced over 4000 orders per day for B2B. Ensured accurate and complete order picking and packing. Supported timely dispatch and delivery. Enhanced process transparency and visibility. Coign Services Used: FMP: Functional Master Planning, Architectural and Engineering Design IWD: Intra Warehouse Design VSA: Vendor Sourcing Assistance Services & Utility Design (SUD) Other case studies Al Abdul Karim Kapico Croma m baazar Allana Nexion Tiles The Sleep Company Load More Optimise your warehouse operations with our efficient designs CONNECT WITH US
Croma
TATA Croma Project Overview Croma-Infinity Retail specialises in consumer electronics and durables, offering various electronic appliances and gadgets. With a strong retail presence through numerous stores across India and a growing online footprint, Croma is well-positioned in both the physical and e-commerce sectors. To support the exponential growth, Croma planned to expand its Distribution Centre (DC) operations in Bhiwandi. Business Challenges Provide a comprehensive design for a Distribution Centre (DC) in a single block of 5.14L square feet. DC operations handle products ranging from large appliances like refrigerators and TVs to miniature gadgets like mobile phones, pen drives, and memory cards for business retail and e-commerce channels. Process study, mapping, and improvements per the business channels and their respective volumes. Ensure process compatibility with the Warehouse Management System (WMS). Identify the ideal mix of human efforts, mechanisation, and automation. Our Solutions Designed an optimised storage mix based on product type, profile, inbound/outbound patterns, and volumes. Conceptualised and streamlined processes from inbound to dispatch, reducing multiple handling of goods. Evaluated all processes regarding cost, flexibility, and necessity to determine automation, mechanisation, or human-driven efforts. Infused mechanisation & automation solutions like lifts, spiral conveyors, motorised conveyors, and put-to-light systems to enhance process efficiency and productivity. Integrated physical processes seamlessly with the planned Warehouse Management System (WMS). Recommended ideal systems to minimise system activities, reduce response time, and improve overall productivity. Designed dedicated processing areas and unidirectional flows for retail and e-commerce operations, eliminating the risk of material mix-ups and enabling easy identification. Enhanced productivity with ergonomic, product-specific, and business channel-specific processing stations. Coign’s Impact Reduced dock-to-stock time for electronic gadgets requiring 100% quality control. Utilised vertical storage volume even for large and heavy appliances. Enhanced picking productivity with the correct mix of storage equipment and ideal size of operational aisles. Improved operational efficiency with the elimination of redundant steps and activities (both physical and system). Created non-conflicting flows for man, material, and machine, boosting productivity and ensuring safety. Coign Services Used: IWD: Intra Warehouse Design VSA: Vendor Sourcing Assistance Other case studies Al Abdul Karim Kapico Croma m baazar Allana Nexion Tiles The Sleep Company Load More Optimise your warehouse operations with our efficient designs CONNECT WITH US
m baazar – Retail & Fashion
M-Baazar Project Overview M-Baazar is a leading fast-fashion garment retail chain with a presence across West Bengal, Odisha, Assam, Tripura, Bihar, Jharkhand, Uttar Pradesh, and Rajasthan, operating over 155 stores. As the company continues to expand, a scalable and efficient warehouse infrastructure became essential to support future growth. Business Challenges The project aimed to: Centralise inter-departmental processes under one facility. Redefine and streamline existing workflows for improved efficiency. Ensure scalability to accommodate business expansion over the next five years. Our Solutions Optimised Warehouse Layout and Workflow Efficiency. Designed a unidirectional workflow for manpower, material, and machines, minimizing conflicts, and mix-ups of materials, while enhancing safety. Inward materials are sorted into 12 specialized departments, ensuring a structured material flow aligned with process-specific requirements. Planned inventory storage with the use of column-supported mezzanines with three levels, along with a provision for adding a fourth level in the future. Enabled the facility to support dispatches to 500+ stores, ranging from premium A+ stores to E-category stores. Added workplace ergonomics & operational enhancements: Ergonomic workstations and improved hygiene facilities to enhance the work environment and boost employee morale. Strategic signage placement facilitates easy identification, clear directional guidance, and reduces operational risks. Dedicated zones for equipment and specific activities minimise material contamination, eliminate operator confusion, and improve overall productivity. Coign Service Used POSA: Pre-Occupational Site Audit IWD: Intra Warehouse Design Service and Utility Design VSA: Vendor Sourcing Assistance Other case studies Al Abdul Karim Kapico Croma m baazar Allana Nexion Tiles The Sleep Company Load More Optimise your warehouse operations with our efficient designs CONNECT WITH US
Allana – Retail & Fashion
Allana Project Overview The F&B client aimed to expand cold storage capacity by 50% to meet the growing demand from Middle Eastern and European markets. The objective was to design a cold-store warehouse for meat and ice cream with a combined total capacity of 12,000 MT. Business Challenges Supplement the in-house technical team with supply chain expertise to design a warehouse that will help the logistics team perform at world-class standards. Identify the optimal mix of resources, human, machines, and space, in different processes and map the flow patterns to complement the warehouse’s fast-paced, large-volume throughput nature. Plan how to increase the storage capacity with the identified storage solution. Make the processes and layout adaptable to WMS implementation. Create a human-operation-friendly environment in a highly MHE active cold-storage warehouse. Our Solutions Structured workflows, inbound from the front and outbound from the rear end, which opened the Anteroom, leading to optimised flow, reduced traffic congestion, and minimised accidents, material mix-ups, and floor deterioration. Reallocated empty pallets to the Anteroom, freeing up staging space for smoother operations. Designed estate roads to align with vehicle types and traffic patterns. Positioned refer charging points on the eve end of the warehouses, enabling multiple refers to be charged well before being docked for loading purposes. Integrated mezzanines in both staging areas to accommodate corporate offices, prayer rooms, hygiene facilities, value-added activities, and welfare spaces for casual workers. Coign’s Impact Improved order fulfilment rate significantly in terms of vehicle loading and offloading. Optimised dock-to-stock and pick-to-dispatch turnaround times to meet the set target time. Enhanced mechanical and human resource utilisation, minimising idle time. Streamlined inbound and outbound staging, reduced dock occupation time, increasing vehicle turnover. Demarcated and allotted necessary service corridors for MHE movement, improving speed and operational flow. Coign Services Used: FMP: Functional Master Planning, Architectural and Engineering Design IWD: Intra Warehouse Design VSA: Vendor Sourcing Assistance Other case studies Al Abdul Karim Kapico Croma m baazar Allana Nexion Tiles The Sleep Company Load More Optimise your warehouse operations with our efficient designs CONNECT WITH US
Nexion Tiles – Heavy Engineering & Construction
Nexion Tiles Project Overview Nexion International, a leading tile manufacturer based in Morbi, Gujarat, is renowned for providing premium-grade tiles and maintaining a strong retail distribution network in India. To support the growing demand in the national market, Nexion has planned to expand its operations. This expansion includes both the adjacent warehouse and the in-plant warehouse and a well-coordinated and efficient workflow. Business Challenges Establish a retail distribution centre to efficiently manage projected volumes for the next 3-5 years. Optimise the flow of man, material, and equipment, improving storage and retrieval processes, enhancing selectivity, and fostering scalable operations focusing on healthy working conditions. Streamline vehicle turnaround time (TAT) to minimise overtime during loading and unloading. Improve the efficiency of handling and storing non-saleable and slow-moving materials. Our Solutions Master-planned the integration of the new warehouse with the existing structure, ensuring adherence to good warehousing practices. Identified the optimal SKU storage methods, focusing on efficient put-away and picking processes to achieve accurate, complete order picking with future scalability in mind. Optimised cube storage and enhanced selectivity by implementing a selective pallet racking system, allowing flexible SKU storage. Standardised storage by categorising pallets into three distinct types to accommodate 29 different dimensions of tiles. Developed custom pallet storage solutions to efficiently accommodate the various dimensions of tiles. Recommended using handheld terminals during picking to minimise errors and enhance process efficiency. Ensured seamless integration of physical processes with the Warehouse Management System (WMS). Coign’s Impact Achieved 100% selectivity of all SKUs. Improved storage capacity by 31%. Enhanced inventory transparency and visibility. Master-planned integration of the new warehouse with the existing structure, ensuring adherence to good warehousing practices. Ensured timely dispatch and delivery. Increased process transparency and visibility. Coign Services Used: FMP: Functional Master Planning, Architectural and Engineering Design IWD: Intra Warehouse Design VSA: Vendor Sourcing Assistance Other case studies Al Abdul Karim Kapico Croma m baazar Allana Nexion Tiles The Sleep Company Load More Optimise your warehouse operations with our efficient designs CONNECT WITH US
The Sleep Company – Home & Living
The Sleep Company Project Overview Our project with The Sleep Company- India’s leading sleep-tech (mattress and furniture manufacturers) company, revolutionizing the comfort industry, involved handling SKUs with odd dimensions and uneven sizes. These included:• Raw Material SKUs: Fabric rolls, foams, and bed frames.• Finished Goods: Smart Grid mattresses, pillows, recliners, and assorted furniture. Pallets and Cage Pallets Design: By analysing the dimensions of all SKUs, we designed a Unit Load Device (ULD) to accommodate these irregular sizes, and designed 6 wooden pallet varieties (1400 x 1300 mm, 2000 x 1200 mm, 2400 x 2000 mm, 2000 x 2000 mm, 2400 x 1200 mm, 1200 x 1200 mm) to cater to all SKUs, along with one cage pallet (1200 x 1800 mm) specifically for large mattress rolls. Once the pallet specifications were finalised, our pallet vendor developed prototypes and tested them in real-world conditions before proceeding with full-scale production. Material Handling Equipment (MHE) Adaptations However, simply designing custom pallets wasn’t enough—we needed Material Handling Equipment (MHE) capable of handling these irregular SKUs, which was the primary challenge. To address this, we reach out to both Indian and global MHE manufacturers, explaining the requirements and assisting them in customising the equipment. Key modifications included:• Widening the fork carriage for improved load stability.• Adding fork extensions to accommodate larger pallets.• Introducing straddles on forklifts to enhance fork stability. According to our MHE vendor, these modifications were first-of-their-kind in India’s mattress industry. An Indian MHE manufacturer took on this challenge, showcasing a strong commitment to innovation, and successfully designed and delivered the customised solution. Customised Storage System & Aisle Space Optimisation Designing an efficient storage system and aisle space was another challenge due to the irregular pallet sizes. Since these weren’t standard pallets, there was no prior data on the required aisle space. To solve this, we worked closely with our racking vendors to develop customised SPR (Selective Pallet Racking) systems with additional components. Additionally, we collaborated with Hyster Yale Materials Handling (our MHE vendor), who shared the project specifications with their German office. After thorough research, they provided the optimal aisle space requirements for handling these customised pallets efficiently between two racks. Results and Impact Optimised Storage Capacity: By designing a solution to store and handle odd-dimension and uneven SKUs, we successfully implemented a high-rise pallet storage system, significantly improving cube capacity utilisation in the warehouse. Enhanced Handling Efficiency & Safety: The shift to mechanised handling methods improved both speed and safety, reducing manual effort while increasing operational efficiency. Improved Productivity: The synchronisation of Man, Material, and Machine led to a notable boost in workforce productivity. Designed a metal cage pallet suited to handle long length rolled mattresses and cage trolleys for cut fabric covers, which were otherwise handled manually. Better Inventory Management: The introduction of cage pallets streamlined inventory counting by enhancing barcode visibility, allowing for quicker and more accurate stock verification. Optimised Order Picking: The cage pallet design improved SKU visibility from a distance, making order picking faster and more efficient. Ergonomic design of workstations coupled with right planning and placement of hygiene facilities, utilities, enhancing good working conditions that improve worker morale. Signage at right places to aid ease of identification, directional guidance, enable information, avoid confusion, and reduce potential risks. Dedicated, specified, and demarcated spaces for all the equipment and activities, avoiding material contamination, operator confusion, and enhanced operational productivity. Sustainability Efforts Our initiative aligns with sustainability goals by enhancing operational efficiency and minimising environmental impact: Reduction in Human Effort: Automation and optimised processes reduce manual labour, improving efficiency and workplace ergonomics. Green Building Compliance: The facility is designed to meet IGBC Platinum standards, ensuring sustainable construction and operations. Efficient Resource Management: Implemented robust scrap, return, and waste management systems to minimise material wastage. Energy Efficiency: The entire facility features an energy-efficient lighting system integrated with natural roof lighting to reduce power consumption. Climate-Responsive Design: The roof has a high Solar Reflective Index (SRI) to reduce heat absorption. Thermal insulation enhances indoor comfort by maintaining stable temperatures. The ventilation system is designed for 6 to 8 air changes per hour, ensuring proper air circulation. These sustainability-driven initiatives not only reduce our environmental footprint but also enhance operational efficiency and employee well-being. Conclusion This project successfully addressed a unique logistics challenge, establishing a new industry benchmark for handling SKUs with odd dimensions and uneven sizes. Through tailored palletization, MHE adaptations, and storage system customization, we enhanced operational efficiency, setting a precedent for future innovations in warehouse management for non-standard SKUs. Coign Services Used: POSA: Pre-Occupational Site Audit IWD: Intra Warehouse Design Service and Utility Design VSA: Vendor Sourcing Assistance Other case studies Al Abdul Karim Kapico Croma m baazar Allana Nexion Tiles The Sleep Company Load More Optimise your warehouse operations with our efficient designs CONNECT WITH US
Grace Supermarket
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. Coign’s Impact Reduced dock-to-stock processing time to meet target timelines. Increased sorting and segregation productivity, processing more orders per day. Improved order fulfilment rates, surpassing current industry standards. Optimised human and equipment resource utilisation. Enhanced process transparency and visibility. Coign Services Used: IWD: Intra Warehouse Design VSA: Vendor Sourcing Assistance Other case studies Al Abdul Karim Kapico Croma m baazar Allana Nexion Tiles The Sleep Company Load More Optimise your warehouse operations with our efficient designs CONNECT WITH US
Borosil
Borosil Project Overview Borosil Ltd., a renowned consumer and life sciences glassware name, began its journey as an Industrial and Engineering Apparatus company. To meet growing demand and increased manufacturing capacity, the company planned a state-of-the-art warehouse adjacent to its manufacturing plant in Jaipur. Business Challenges Ensure efficient transfer of semi-finished goods (SFG) and finished goods (FG) from the adjacent manufacturing plant to the warehouse. Streamline the inbound movement and handling of SFG, FG, and packing materials (PM) while preventing mix-ups. Select and design an optimal storage mix to accommodate SFG, FG, and PM under one roof. Manage the return of picked SFG back to the factory. Enhance picking, sorting, and dispatch processes. Alleviate congestion in the staging and pack-and-hold areas. Our Solutions Implemented an inter-facility motorised conveyor system integrated with automated sorting technology to transport materials to the warehouse while segregating them by type and designated storage zones. Designed custom storage solutions for specific material needs, including a pallet shuttle system for SFG, selective pallet racking and multi-tier shelving for FG, and dedicated shelving for PM. Developed unidirectional, streamlined workflows for SFG, FG, and PM, ensuring material segregation, minimising contamination risks, and improving operational productivity. Strategically aligned the conveyor system with shelving levels to enable synchronised operations, significantly enhancing picking efficiency. Engineered an automated sorter system to facilitate route-specific segregation of FG. Utilised the unused height above the docks by designing a dedicated mezzanine pack-and-hold area, maximising space efficiency and functionality. Coign’s Impact Optimised storage capacity through appropriate storage mix based on product types, inbound/outbound patterns, and volumes. Enhanced productivity in put-away, picking, and sorting operations. Minimised material handling, contamination risks, and product damage. Improved order fulfilment rates and accuracy. Eliminated congestion in processing and staging areas, preventing delays and errors. Coign Services Used: IWD: Intra Warehouse Design VSA: Vendor Sourcing Assistance Other case studies Al Abdul Karim Kapico Croma m baazar Allana Nexion Tiles The Sleep Company Load More Optimise your warehouse operations with our efficient designs CONNECT WITH US
Clariant
Clariant Project Overview Clariant Chemicals India expanded its production plant in Maharashtra to double capacity, catering to domestic and international markets. The expansion necessitated robust infrastructural and functional support for efficiently storing and distributing raw materials, semi-finished and finished goods. Business Challenges Identify the ideal storage system to accommodate all SKUs in their respective volumes. Address the existing challenge of using non-standard pallets and the resulting storage issues. Make the processes adaptable to WMS implementation. Ensure an optimal mix of human efforts and mechanisation to complement a fast-paced environment. Integrate ways to improve safety measures in the distribution centre. Our Solutions Developed a comprehensive mass receipt and fulfilment process for seamless movement between the production plant and warehouse. Conducted a simulation to identify and standardise pallet types for efficient SKU handling and storage. Designed WMS-friendly processes to enable complete system integration. Recommended a resource requirement and utilisation matrix for efficient warehouse operations. Engineered the warehouse to receive and dispatch material from three sides, with the fourth side planned for future expansion. Created a unilateral flow of man and material to minimise inefficiencies. Planned adaptable infrastructure and workflows to integrate with future systems seamlessly. Coign’s Impact Reduced dock-to-stock processing times to targeted benchmarks. Eliminated staging area congestion and bottlenecks. Maximised storage capacity utilisation. Improved the ease and safety of man, material, and equipment movement, significantly reducing confusion and accidents. Reduced overall warehouse maintenance costs by isolating and confining specific activities. Coign Services Used: IWD: Intra Warehouse Design Service Utility Design VSA: Vendor Sourcing Assistance Other case studies Al Abdul Karim Kapico Croma m baazar Allana Nexion Tiles The Sleep Company Load More Optimise your warehouse operations with our efficient designs CONNECT WITH US
