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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

  1. Designed an optimised storage mix based on product type, profile, inbound/outbound patterns, and volumes.
  2. Conceptualised and streamlined processes from inbound to dispatch, reducing multiple handling of goods.
  3. Evaluated all processes regarding cost, flexibility, and necessity to determine automation, mechanisation, or human-driven efforts.
  4. Infused mechanisation & automation solutions like lifts, spiral conveyors, motorised conveyors, and put-to-light systems to enhance process efficiency and productivity.
  5. Integrated physical processes seamlessly with the planned Warehouse Management System (WMS).
  6. Recommended ideal systems to minimise system activities, reduce response time, and improve overall productivity.
  7. Designed dedicated processing areas and unidirectional flows for retail and e-commerce operations, eliminating the risk of material mix-ups and enabling easy identification.
  8. 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.

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