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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.

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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.
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Our Solutions

  1. Factored storage system scalability to accommodate over 5,00,000 fresh inventory daily across all brands efficiently.
  2. Implemented unilateral flow for both people and materials.
  3. 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.
  4. 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.
  5. 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.
  6. Achieved seamless integration of physical processes with WMS.
  7. Boosted productivity with ergonomic, durable checking and packing stations, optimal LUX levels, and stringent surveillance.
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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.
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Coign Services Used:

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Architectural blueprint of a modern warehouse facility designed by Coign Consulting.
Architectural blueprint of a modern warehouse facility designed by Coign Consulting.

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