40% Throughput Gain in 3PL Operations
Operational intelligence and process redesign for a third-party logistics provider
A growing 3PL operator was struggling to scale through peak periods without proportional labor cost increases. Manual picking errors were running at 2.3%—generating costly returns—and management lacked real-time visibility into warehouse throughput and order status.
Peunier conducted a comprehensive operational audit followed by a systematic workflow redesign, implementing a real-time warehouse analytics dashboard, optimized pick path algorithms, and staff performance visibility tools.
Operations Audit
2-week deep-dive mapping all warehouse processes, recording time studies for 43 task types, and analyzing 6 months of order and error data.
Root Cause Analysis
Identified 7 primary root causes of picking errors and 4 major throughput bottlenecks using structured fishbone and process mapping analysis.
Workflow Redesign
Redesigned pick path logic, zone assignments, and replenishment triggers—reducing average pick travel distance by 28%.
Analytics Dashboard
Deployed real-time warehouse operations dashboard giving management live visibility into throughput, accuracy, and labor productivity by shift and zone.
Their operational audit was the most thorough assessment we've experienced. Within 8 weeks we had a 40% throughput improvement—without adding a single new employee.