Client operated 3 warehouses and managed more than 120 40-foot storage containers.  Client engaged Walker to assist with cost control and customer service issues such as:

• Excessive scrap and loss claims
• Poor order accuracy
• Rising backlog
• Poor visibility on parts’ receipt
• No supply-chain cost transparency
• Over 100 transportation vendors

Walker was engaged to coordinate over 200 suppliers in 15 countries and manage the related carriers to meet JIT delivery to forecast and line- side stocking needs for 8,000 parts in 22 kits daily (5.5 million picks/year)

• Implemented the following processes:
  • Kan Ban to line
  • Accurate inbound labeling
  • Inbound exception management and claims management
• Designed local milk-run schedule
• mproved packaging

• Reduced warehouses from 3 to 1
• Reduced transportation vendors from 100+ to 20+
• Scrap/damage rate reduced to near-zero
• Order accuracy improved to greater than 98%
• Pick cycle reduced from 4 days to 3 improving backlog management improved
• 24x7 on-demand “hot pick” response
  • 95% within 2 hours; remaining within 4 hours
• Part receipt visibility available within 2 hours
• Increased freight weight throughput by 49%
• Decreased cost per hundred weight by 46%
• Decreased expedited shipment costs by 40%
• Total savings ~$4M