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.