GROWTH & EXPANSION
SITUATION
Freshdirect-NYC's first and biggest e-grocer outgrew their Long Island City Start-UpPlant and was looking to build a new Headquarter housing their complete internal manufacturing as well as their main warehousing and distribution center.
THEIR NEED
Re-envisioning the manufacturing process, building production capabilities, process and design layouts to 3.5x growth projection, decide on software solutions for the different area of operation and their integration, move complete operation from building to building with minimal customer impact.
PRIMARY SERVICES PROVIDED
- Design 120K square feet layout for food manufacturing space producing via MTO (Make-to-Order) and MTS (Make-to-Stock) production strategies.
- Production layouts for RTE (Ready-to-Eat) and RTC (Ready-to-cook aka raw meat & seafood handling) & Transitional production area (Kitchen "raw-in & RTE out") & food safety & HACCP flows.
- SAP ERP enhancements for production wave logic's, Production planning & SKU set up.
- Participation in 3-way software integration between SAP (ERP), Manhattan Associates (WMS) & Intelligrated WES systems including Design requirements & UAT.
- Involved in 2-year build phase with permanent onsite office.
- Participated in management & staff training material.
- Development & execution of transition scenarios, building move-out/in.
RESULTS
Achieved desired output capabilities and 15-20% laborefficiencies for comparable areas. Successful move Kitchen of 180 personnel, 200 truckloads of materials, equipment & small wares from Sunday postproduction moveout to Wednesday afternoon production start in new facility. Smooth "parallel transition phasing" for MTO areas while operating departments in both facilities to support pick & pack, dispatch & transportation transition.
Extensive learnings & solution finding overcoming challenges that surfaced post
move in warehouse operations.
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