CPG Warehouse Throughput

Transformed B2B warehouse to support rapid B2C delivery

A consumer products manufacturer needed to transform its traditional Business-to-Business truck-load delivery model to support Business-to-Consumer delivery. Its existing planning/scheduling, operations, and warehouse capabilities were unable to cost effectively delivery goods directly to end consumers. Large seasonal variances were particularly challenging.


  • Conducted an end-to-end capacity assessment to identify process and systems issues critical to overall capacity and supporting seasonal volume surges
  • Improved planning/scheduling and installed a Sales & Operations Planning process
  • Installed new warehouse layout and new equipment
  • Collaborated with IT staff to implement new warehouse software supporting critical wave pick lists and shipping labels for efficient picking, packing, and shipping

Results: Improved throughput from 3,500 packages per day to 24,270 per day with no additional labor.

Kormac Results - Enhanced warehouse processes and systems for rapid product delivery via FexEx & UPS - Improved throughput by 593%, from 3,500 packages per day to 24,270 - Achieved capacity expansion without additional labor. CS251