A consumer products business producing and selling dairy-based beverages, infant nutrition, cheese and desserts in many European countries, in Asia and in Africa via its own subsidiaries.
Working as Arla Foods's implementation partner, Rocket Consulting helped create an award-winning state-of-the-art dairy using SAP's Supply Chain Execution software that has helped Arla Foods support its continued growth and success in supplying a full range of fresh dairy products to the major retailers and food-service customers. The business has an annual turnover of £2 billion and is the UK's number one dairy company.
Arla UK has an ambitious growth strategy and the new one-billion litre fresh milk dairy was directly in line with the company’s growth and environmental ambitions, and its commitment to support British dairy farming. In addition, a new distribution centre was planned for Hatfield.
Initially, Arla had implemented WM in their SAP ERP system, later moving on to a decentralised version of SAP WM. Demand for new functionality increased so a new solution was needed to support their strategy of standardisation.
The company decided to go ahead and invest in a new SAP Extended Warehouse Management (EWM) system at both greenfield sites. Part of the reason for this was to make use of the ‘
Arla had worked with Rocket when implementing Warehouse Management at another location. Rocket worked with Arla at the early stages of the project lifecycle, initially to help them understand the benefits of using EWM.
As the chosen EWM implementation partner for Arla, Rocket was responsible for the configuration and build of the entire EWM solution under their project management and implementation methodology. This was successfully achieved with a diverse team of experienced EWM solution architects and consultants, specialist developers and mobility experts responsible for the provision and deployment of the various mobile aspects of the solution including RF, Voice, RFID, and Mobile Device Management.
"I can’t say enough good things about Rocket. They understand the business and our processes. Some of the vendors we’ve used in the past have been good at the technical stuff, but they don’t really think about the impact
- Colin Fearon, Senior Solution Consultant for Warehouse and Distribution at Arla
Inconsistencies in global article identification, labelling and inventory processes have led to master data proliferation, increased inventory holding and confusing offers to the consumer, ultimately creating significant inventory holding and handling costs impacting over 1200 articles in over 2500 stores in 61 countries.
Existing SAP ECC IS-Retail processes will be re-engineered introducing batch management and procurement to all product variants with substitute GTIN as the basis for master data and process simplification.
• Significant reduction in inventory holding and handling cost
• Reduction in article proliferation
• Simplification of in-store receiving and inventory management
• Compliant article traceability
• Streamlined supplier ordering process
• Simplified offer to the customer
One of the biggest challenges Plaisio faced was having to manage the organisation across five main distribution centres in different locations, with each of these warehouses serving different product ranges. A step change was needed, and Plaisio’s president and CEO, Mr. George Gerardos, made the decision to invest in the biggest, state of the art distribution centre in Greece, housing all of their offices and operations under one roof.
• ECC 6 & IS Retail
• SAP Warehouse Management
• SAP Task and Resource Management
• TRM Enhancement Pack
• Extended RF Material Enquiry
• Psion Teklogix Handheld RF Devices
• Zebra Mobile Printers
• Savoye Tote Picking & Sortation Conveyor
• Reduced the physical workload by 70% for checking and packing
• Significant cost savings by consolidating 5 warehouses into one
• 20% increase in productivity for replenishment and put away activities by the fork lift operators
“Rocket Consulting has been involved in designing and implementing all the physical and system processes within Plaisio’s state of the art warehouse. Throughout all the Go Lives, from the smallest to the biggest, we have been impressed by their commitment, professionalism and their overall expertise.”
Costas Stavroulakis, Plaisio’s Project Manager.
KNDLs new off-trade 600,000 square foot national distribution centre comprises of dense very narrow aisles (VNA) racking to maximise storage capacity. While this is a very space efficient layout, VNA storage needs careful optimisation of workload and material handling equipment (MHE) to ensure high throughput and gain the best efficiency and load-balancing. As part of a full SAP WMS and mobile workforce implementation at the site, KNDL needed a design to allow fast simulation and optimisation of workload to ensure the VNA and warehouse throughput was kept high.
Fast and easy understanding of the warehouse situation was critical to any solution due to the dynamic nature of warehouse workload, people and MHE. Therefore, a real-time visualisation of warehouse layout, workload and resources was chosen and the Rocket Virtual Warehouse Monitor and Simulation Tool for SAP Extended Warehouse Management was deployed. The Virtual Warehouse Monitor provided KNDL visibility of where work was being placed into the warehouse in real-time, enabling smarter operational decision making based on visual insight. Effectively this allows KNDL to simulate what would happen, for example, when a vehicle staged at a door and where put away or pick activities were starting of finishing.
• Optimisation of very narrow aisle storage
• Faster, smarter pro-active operational decision making
• MHE Load balancing and interleaving
• Maximised distribution centre throughput
Rocket’s store of SAP Add-ons helps our customers accelerate SAP implementations and extend the benefit core SAP platforms while reducing the need for bespoke project development. Our Rocket Packs cover a wide range of Supply Chain and Operations execution activities aimed to drive up return in investment and process innovation.
The clothing retailer’s transformation program was already in-flight with an SAP implementation underway. Before commencing the supply chain phase the board wanted to have a subject matter expert validate the anticipated approach and SAP architecture for this phase, to ensure they were investing in the right solution for their supply chain; either SAP Warehouse Management (SAP WM) or SAP Extended Warehouse Management (SAP EWM) or SAP EWM on HANA.
Rocket carried out a series of interviews, site visits and workshops, following our proven methodology, analysis of their business, operational and IT strategy and evaluating SAP Warehouse Management and SAP Extended Warehouse Management against these and key functional requirements, anticipated benefits and forecast total cost of ownership.
The resulting Supply Chain System Review report to the board demonstrated how each of the supply chain platforms would contribute to achieving their business, operational and IT strategy and the relative fit, benefits and costs against the key functional requirements.
The report allowed the board to make an informed decision on both the short and longer term strategy.
• Able to ratify the decision that they were making on their investment in SAP software
• A short term investment in SAP WM was viable with a longer term view to move to EWM
• Clear understanding of the incremental benefits for Jack Wills between SAP WM, SAP EWM & SAP EWM on HANA
• Clear understanding on the relative differences in implementation and Total Cost of Ownership
With a very diverse product range of over 20,000 SKUs across a wide range of vendors, from small packages like batteries to large, awkward shaped items such as signs, material handling costs were escalating and Brady faced huge challenges around efficient material handling, in particular receiving mixed shipments from multi-vendor and product picking.
Rocket implemented topVOX voice system directly integrated into SAP Warehouse Management with no middleware. The voice optimised receiving and put away process has allowed Brady to efficiently manage mixed incoming pallets of product, separate them very quickly into trolleys for put away and manage tours around the bins, all executed by voice. Brady now also benefit from voice optimised picking transactions, providing further efficiency gains.
Following Rocket’s mobility & technology best practices and methodology for supply chain and operations a voice optimised product handling process was created to seamlessly integrate within the SAP Warehouse Management. Rocket’s expertise and certified partnerships covered the turnkey solution from mobile device selection & provisioning through to Voice process design & implementation using topVox Lydia Voice Suite for SAP running on topVox Voxter voice optimised mobile devices. This solution, combined with an optimised pallet deconsolidation and trolley putaway process add-on from Rockets SAP extension library, transformed the receiving and picking processes by giving new levels of speed and ease of working across the wide product range.
• Over 50% time saving with optimised receiving & put-away process
• Picking time – saving of 25% in picking times
• Material handling cost reduced by 20% saving
• Very fast workforce onboarding thanks to intuitive Voice enabled ways of working
• Reduce staff training costs
Rocket is a certified Honeywell partner, Vocollect Voice implementation partner and Topvox Lydia Voice Suite implementation partner with proven expertise in the provision of mobile, voice, RFID and IoT solutions that underpin Supply Chain and Operations excellence.
CLL has always enjoyed the status as a luxury brand, but historically their back office has needed to work hard to keep up. They were quickly running out of warehouse space, and stock was not always easily located. Capacity management was ineffective, and it was taking far too long to put goods away.
CLL’s parent organisation had been using SAP since 1998, but had not yet extended their implementation to include Warehouse Management. They looked at 3 partners and Rocket Consulting stood out with their presentation, style and capability.
Hallmark UK had multiple business units each with their own ERP system and stock ownership. All were working in the same warehouse and with non-aligned processes on two different warehouse management systems.
With guidance from Rocket, Hallmark selected to implement SAP Extended Warehouse Management (EWM) in support of their range of needs, including its specific functional requirements, the multiple ownership of stock and multiple ownership of stock and multi-ERP integration, the costs involved and their strategic direction.
"Together we formed a strategic partnership to create new platform allowing us to bring more business into the operation. The result was a success and an SAP first"
John Franey, Logistics Director at Hallmark UK
To help bring the SAP Warehouse Management aspect of their current project back on track and help overcome several big challenges to business critical processes in the final stages of a large SAP R/3 Enterprise implementation project.
Rocket provided a team of consultants and worked within tight deadlines to detail the key priorities. After quickly establishing the Blueprint Design Rocket implemented SAP R/3 Warehouse Management and Task & Resource Management based solutions to support business critical processes.
'Rocket Consulting coordinated and quickly established the Warehouse and Task & Resource Management blueprint within very tight deadlines. We couldn’t have gone live with the full SAP Warehouse and Task & Resource Management scope without their assistance".
Laithwaites previously operated out of two distribution centres and 70% of the distribution operation was outsourced, they needed to reduce distribution costs and increase efficiency and turnover, whilst improving quality and control.
Rocket designed a state of the art warehouse system for Laithwaites’ new distribution centre, with high level automation controlled by the SAP ERP Warehouse Management.
"As a result of the new SAP ERP warehouse management system that Rocket developed for us we now have a highly productive and accurate warehouse meeting customer needs, and we have been able to increase our through-put by 50%. The new system has way exceeded our expectations". Kevin Hanley Operations Director
KNDL needed to implement a dedicated IT infrastructure to entice customers to take advantage of its shared distribution network.
Following a strong recommendation from SAP, Rocket Consulting was engaged by KNDL to implement the SAP Logistics Execution & Warehouse Management solution.
"Rocket Consulting is a team of highly competent supply chain specialists. As well as being a friendly bunch, they have an absolute drive to achieve the objectives".
Allan Jagger, KNDL’s Business Systems Manager
To drive out the value from their investment in their SAP IS Retail ERP.
Rocket Consulting were engaged as Harrods SAP supply chain and warehouse management partner. Rocket provide Harrods with a single point of support, from strategy and best practice opportunities, through process optimisation and down to the detailed software and technology implementation.