Case Study with Prime Print Group

The commercial printing business needed support to model a range of different scheduling approaches within its operation to increase it's production capacities to support the significant growth it was undergoing.

Client Overview

Precision Proco, formerly the Prime Print Group, is a commercial printer creating personalised printed communications and products to it’s B2C customers. The company despatched up to 7,500 orders per day from it’s factory and warehouse in Mansfield, UK.

Project Objectives

The company was experiencing rapid growth especially during peak and wanted to explore options to improve their operations and fulfilment capacity by reviewing their work release and scheduling process.

  • Identify an operational solution that would help manage increasing order volumes in a constrained footprint and reduce bottlenecks
  • Support the business to prepare for the businesses’ forthcoming peak trading period

Project Approach

  • Swift familiarisation of the current operations and scheduling processes.
  • Developed and calibrated a simulation model to replicate the current work release schedule to act as a baseline.
  • Considered a range of alternative scenarios with variables including batch sizes, works hours, and wave release patterns.
  • Assessed the impact of deploying basic warehouse automation equipment including conveyors and pick-to-light technology.
  • Compared the outputs of each scenario against the baseline based on the key criteria of footprint, productivity and capacity.
  • Made recommendations based on the modelling output alongside a roadmap to achieve the new ways of working.

Project Results

  • Provided various operational recommendations to achieve the project goals including the optimal batch sizes by each product category, an adjustment of operating hours at peak and the implementation of backward scheduling logic across the operations.
  • Feedback on potential operational systems and suggested warehouse technologies to explore to deliver greater efficiencies and utilisation of warehouse footprint.

Client Feedback

BoxLogic worked closely with the team and did a great job to simulate various feasible options. Their recommendations should help us move towards increased capacity and throughput.
Jon Tolley

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