3.4 Million
Gift Sets Packed Each Year
99%
Packing Accuracy
100%
Retailer Launch Dates Hit
Objective
To effectively mange the the receipt, storage, quality control, and production of 3.4Million componentry items across multiple gift ranges, ensuring correct placement, fitment, box build accuracy, full traceability, BBE Controls and on-time delivery to a high street grocers such as Tesco, Iceland & B&M's.
Process
Receive all stock - circa 3.4 Million componentry items for a variety of gift variations, booking receipts into the WMS System
Conduct quality checks on all incoming items to confirm this is no damage or contamination
Allocate appropriate storge space for componentry and finished goods
Generate gold seal samples for production specifications and submit for client approval prior to production.
Critical path designed to meet retailer launch dates
Generate packing picks for requires stock, ensuring BBE dates exceed six months from the expected in-store delivery date.
Allocate and secure staff, QC and service support for the production run.
Perform QC checks during production for correct placement, box build and ale variations
Record BBE and batch codes for each product produced to maintain traceability
Store Finished Goods securely until dispatch
Dispatch as per required schedule, generating goods-out paperwork for finished goods.
Solution
A structured, end-to-end workflow established to manage a high-volume componentry, multiple variations and stringent QC requirements. By integrating WMS controls, comprehensive quality checks, production planning, staff allocation, and traceability processes, the operation ensures:
Accurate assembly and box builds
Compliance with client-approved specifications
Robust traceability for potential recalls
Efficient and timely delivery to store
This approach guarantees product quality, operational efficiency, and reliable execution across all three ale variations.