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Customer Case Study - Greencore Group plc

Gideon Hillman Consulting complete Warehouse Optimisation

 warehouse improvement and optimisation
Following their previous network strategy optimisation project back in 2014, Greencore Group wished to optimise their facility in 2016.


Greencore Group engaged the Warehouse and Logistics Specialists at Gideon Hillman Consulting to conduct further project work, this time requiring assistance with warehouse optimisation for Greencore’s Prepared Meals (GPM).


Established in 1991, Greencore Group business diversified into convenience food in 2001; UK Convenience is made up of three divisions, Food to Go, Prepared Meals, and Grocery.


Greencore’s Prepared Meals (GPM) business produces chilled ready meals, chilled sauces, chilled soups and quiches for the major retailers in the UK. The business, like most of the categories in which it operates, is largely private label, although Greencore also produces under license for Weight Watchers, Little Dish and Cinnamon Kitchen. GPM’s key clients include J Sainsbury’s, Asda, Co-op, Budgens and Aldi, although the primary client and the driver of both volume and service is Sainsbury’s.


GPM asked Gideon Hillman Consulting (GH) to assist the business in the areas of warehouse layout and optimisation, operating processes and a review of the current Warehouse Management System (WMS).


Under the scope of this project, Gideon Hillman Consulting were required to carry out a review of the existing GPM warehouse operations, including pick/pack and despatch, efficiency of product storage, handling and picking regimes, process and storage bottlenecks, facility layouts, current deployment of warehouse staff and equipment, picking and replenishment strategies, shift patterns, staff resource plan and warehouse management team structure, facility constraints for existing volumes and future growth volumes, metrics for core activities, WMS operational requirement specification to best support the optimised workflows; and to review current and if required, provide an updated set of Standard Operating Procedures (SOPs) to support the optimised layouts and workflows.


The GH team of specialist Logistics and Warehouse Consultants conducted an initial ‘kick-off’ meeting with the GPM consultant team and key client stakeholders to agree the project approach, timetable, key milestones, roles and responsibilities, as well as confirming GPM’s business activities and future plans.


In order to properly identify and develop optimised layouts, workflows and operational procedures the Specialist Logistics and Warehouse team reviewed various GPM processes, including but not limited to: product flows and volumes, operational hours of the facility, pick/pack and despatch procedures, and growth projections for their three to five year planning horizon; In order to fully understand the operation and develop the future state.


Completing this project, the GH Specialist Warehouse Consultants provided GPM with recommendations for measures to improve productivity and capacity of their warehouse, to optimise picking strategies, shift patterns, resource plans and warehouse management team structure, with an SOP’s manual to support their optimised layouts, process and workflows; all whilst simultaneously highlighting best practices and opportunities for improvement for GPM.

Click Here to read about previous projects by Gideon Hillman Consulting 

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Gideon Hillman Consulting is a trading name of The Supply Chain Consulting Group Ltd is registered in England and Wales.
Company Registration No: 09751027. Registered office at Highdown House, 11 Highdown Road, Leamington Spa, CV31 1XT. UK
A supply chain and logistics specialist with knowledge of ERP & MRP integration, logistics network planning and inventory policy development

The Chartered Institute of Logistics and Transport fsdf SHD Logistics Awards Finalist New Facility 2016 Winner of the UKWA Technical Innovation Award 2016 The Logistics Awards Finalist Operation (large) 2018 QMS ISO 9001 Registered The Logistics Awards Finalist New Facility 2018 Supply Chain Excellence Awards 2018 Finalist Institute of Consulting