FirstCry
FirstCry Project Overview Firstcry is a leading eCommerce platform specialising in pre-natal and post-natal baby care products. It aims to expand its footprint in South India by establishing a fulfilment centre in Bengaluru, Karnataka. The facility was designed to cater to a diverse client base, including owned retail outlets, institutions, and distribution partners. Business Challenges Identify the ideal storage system to optimally accommodate more than 2 lakh SKUs in their respective volumes. Implement efficient picking, sorting, consolidation, and dispatch methods to accelerate order fulfilment. Ensure the processes are adaptable to WMS implementation. Identify the optimal mix of human efforts and mechanisation to complement the fast-paced nature. Integrate ways to improve safety measures in the distribution centre. Our Solutions Designed a unidirectional flow for seamless movement of personnel and materials. Implemented a scalable multi-tier storage system to maximise the cube capacity of the distribution centre. Enhanced operational efficiency through automation, reducing manual intervention and increasing capacity to service more stores: Barcode readers during picking – Minimised strain and fatigue. Separate conveyors for single-order and multi-order SKU vertical movement – Improved order processing speed. Put-to-light systems for destination or store-specific sorting – Ensured precise store-wise packing. Lightweight handheld packing slip printers – Made labelling effortless. Seamlessly integrated the physical workflows with the Warehouse Management System (WMS). Enhanced productivity with ergonomic trolleys, durable checking and packing stations, optimal LUX levels, and enhanced surveillance systems. Designed an end-to-end system for material storage, movement, and efficient scrap management. Developed comprehensive electrical systems and fire safety solutions, including detection, prevention, and firefighting mechanisms. Recommended a resource requirement and utilisation matrix to optimise warehouse operations. Provided solutions that addressed the drawbacks of the rented facility effectively. Coign’s Impact Raised picking efficiency by 18%. Increased storage capacity by 30%. Boosted the number of chemists for distribution by 40%. Reduced congestion & accidents by 90%. Improved inbound & outbound TAT by 45%. 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
Bazaar Kolkata
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. 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
Mohani Tea
Mohani Tea Project Overview Mohani Tea Leaves envisioned expanding its manufacturing capacity by establishing a production centre for tea bags and a central warehouse for national distribution to top global brands like Walmart and Carrefour. The focus was on creating an efficient, best-in-class layout and design that adheres to best practices and audit requirements. Business Challenges Limited land availability and irregular plot shape. Criss cross movement of materials leads to mixing of raw materials (RM) and packaging materials (PM). Under-utilised storage bins, resulting in capacity shortages for new arrivals. Excessive input material at filling lines causing congestion. Conflicting line feeds and line-out SKUs. High vehicle turnaround time (TAT) leading to overtime and demurrage costs for export containers. Low throughput and productivity due to an inefficient layout. Our Solutions Established unidirectional flow to eliminate the risk of material contamination. Designed a flexible storage mix for packaging materials (PM) and finished goods (FG) based on consumption patterns and picking requirements. Streamlined the flow of bills of material in alignment with daily production plans, ensuring efficient feed to respective hoppers and filling lines. Integrated conveying systems with packing lines and sortation by SKU for swifter storage. Implemented Just-In-Time line feeding for packaging materials (PM). Conceptualised automating key processes, including weighing, counting, boxing, sealing, and label printing for finished goods (FG). Introduced a productivity-driven approach to resource calculation, optimising layout and resource planning. Integrated blending units with raw material storage tanks for smoother operations seamlessly. Coign’s Impact Reduced vehicle and offloading TAT by 25 minutes. Decreased dock-to-stock TAT by 15 minutes. Minimised multiple handling of raw materials (RM), reducing spillage and wastage by 3-4%. Achieved a reduction in packaging material (PM) inventory by Rs 3.0 Cr through Just-In-Time (JIT). Boosted overall productivity by 18%. Increased production capacity by 40%. Reduced handling damages. 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
