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Wellness Forever

Project Overview

Wellness Forever is a 24/7 retail chain specialising in pharmaceuticals, healthcare, and FMCG products that operates across Maharashtra and Goa. With a growing network of outlets and a robust distribution system supported by its Mother Distribution Centre in Bhiwandi, the client aimed to expand storage and service capacity.

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Business Challenges

To achieve the following objectives without increasing the warehouse footprint (area):
  • Scale up the storage capacity.
  • Expand service capacity from 180 to over 350 stores.
  • Improve order fill rate (OTIF).
  • Address issues like contamination risks and multiple handling of goods.
  • Reduce manual effort and alleviate worker fatigue.
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Our Solutions

  • Optimised warehouse capacity with multi-tier shelving and column-supported mezzanines.
  • Streamlined operations by:
    • Introduced motorised conveyors with automated sorters, enhancing order sorting and destination alignment while saving time and effort.
    • Designed ergonomic, multi-functional checking and packing stations to boost productivity and worker comfort.
    • Strategically segregated and aligned inward and outward processing stations across multiple levels for operational efficiency.
  • Installed lifts and gravity spirals for seamless vertical movement, significantly reducing manual intervention and physical strain.
  • Integrated Appropriate Automation and Mechanisation
    • Improved order processing time and order accuracy.
    • Minimised material damage.
  • Improved OTIF by:
    • Integrated hands-free in-rack picking with tray roller conveyors and tablet-mounted mobile cradles for improved picking and put-away processes.
    • Enhanced SKU visibility and traceability with barcode-enabled operations, reducing processing time.
    • Implemented in-rack inclined conveyors to improve material movement while minimising time, effort, and damage.
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Coign’s Impact

  • Reduced dock-to-stock time from 70 mins/vehicle to 40 mins/vehicle.
  •  Improved picking accuracy from 96.2% to 99.4%.
  • Expanded the number of stores serviced from 180 to 300.
  • Boosted the order fulfilment rate from 200 orders/ hr to 600 orders/ hr.
  • Increased checking & packing productivity from 40 to 60 orders/hr.
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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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