Warehouse shelving and products

04/17/2025

Real-World Warehouse Optimization: Results & Impact

Learn how GEODIS warehouse optimization delivers 15-60% efficiency improvements through real case studies, implementation processes, and measurable business benefits for 3PL operations.

The true value of any logistics optimization solution lies in its real-world impact. At GEODIS, our integrated warehouse optimization approach doesn't just promise theoretical benefits—it delivers measurable results across our warehousing operations. By combining strategic inventory placement with intelligent order processing, we're transforming warehouse efficiency with improvements ranging from 15% to 60% even in already well-organized facilities.

 

This article explores the concrete business outcomes of our warehouse optimization solution through detailed case studies, implementation insights, and the tangible benefits that impact your bottom line. You'll discover how our data-driven approach translates directly into reduced costs, increased throughput, and improved service levels—all with minimal implementation effort and disruption to your ongoing operations.

Key takeaways

 

  • GEODIS warehouse optimization delivers efficiency improvements of 15-60% across diverse client implementations in our facilities
  • Implementation is rapid (2-3 weeks per component) with no additional cost for GEODIS clients
  • Case studies show concrete results including 47% reduction in aisle visits, 30% increase in units processed per hour, and up to 82% reduction in total aisle visits
  • Business benefits extend beyond operational metrics to workforce optimization, cost reduction, and enhanced service level performance
  • Implementation follows a structured four-step process with minimal disruption to ongoing operations
  • The solution is adaptable to diverse warehouse environments including traditional, automated, and mixed operations

Rapid deployment, immediate results

One of the key advantages of our warehouse optimization solution is how quickly we can implement it and how soon you'll see results:

 

  • Efficient implementation: Each component (slotting and wave optimization) takes just 2-3 weeks to implement
  • No additional cost for GEODIS clients
  • Minimal disruption to ongoing operations
  • Immediate benefits visible shortly after implementation

 

This quick implementation timeline means you can realize benefits almost immediately after deciding to optimize your operations.

 

The solution works with our existing warehouse layouts and infrastructure. While it may recommend relocating some inventory based on movement patterns, it doesn't require significant physical changes to warehouse setups.

 

Our implementation approach is both thorough and efficient:

 

  1. Data collection and analysis: We gather your historical order data and analyze the facilities we run on your behalf
     
  2. Solution configuration: We optimize our algorithms to your specific operations
     
  3. Execution and implementation: We apply the optimized algorithms to your operations
     
  4. Performance validation: We track key metrics and compare with pre-implementation baselines

 

This streamlined process ensures rapid value delivery with minimal operational disruption.

Ready to transform your warehouse efficiency? Contact our logistics experts to learn how GEODIS warehouse optimization can deliver measurable results for your operations in our facilities. Get in touch with GEODIS.

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While results vary based on initial warehouse organization and operational characteristics, all of our pilot clients have seen efficiency gains that directly benefit their bottom line. Even well-organized facilities typically see 15-20% improvements, while less optimized operations experience even more dramatic gains.

 

These metrics translate directly into business value:

 

  • Reduced labor costs through more efficient picking
  • Increased throughput capacity without additional resources
  • Enhanced ability to meet service level agreements
  • Improved space utilization throughout the facility
  • Better workforce utilization and productivity

Case studies: Real-world optimization impact

Our warehouse optimization approach has delivered measurable results across diverse client operations. Here are three detailed case studies that demonstrate the adaptability and effectiveness of our solution.

 

Case study: Retail distribution center

We implemented our wave pick optimization in a retail distribution center to improve efficiency for manual picking operations:

 

Challenge:

 

  • Excessive picker travel time
  • Inefficient order batching
  • Multiple pickers handling 500+ orders per wave

 

Solution:

 

  • Implemented wave optimization to intelligently batch orders
  • Created optimized pick paths to minimize aisle visits
  • Balanced workload across available pickers

 

Results:

 

  • 65-70% reduction in distance traveled
  • Aisle visits decreased from 139 to 56 (60% reduction)
  • Processing capacity increased significantly

 

The implementation transformed how orders were grouped and processed, enabling pickers to fulfill more orders in less time with reduced physical effort. This case demonstrates how our solution can dramatically improve efficiency in traditional picking environments with minimal changes to existing infrastructure.

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Case study: eCommerce with automated picking

A high-tech distribution facility using Locus robots faced significant congestion during peak periods:

 

Challenge:

 

  • Robots clustering around high-velocity items
  • Single pick front locations creating bottlenecks
  • Valuable warehouse space occupied by slow-moving inventory

 

Solution:

 

  • Identified 26 high-velocity SKUs contributing to 50% of total volume
  • Distributed these items across four locations in different aisles
  • Relocated dead/slow movers to designated areas
  • Created multiple wave templates for varied robot paths

 

Results:

 

  • 50% reduction in congestion compared to the previous peak season
  • More balanced robot traffic throughout the facility
  • 30% improvement in Units Per Hour

 

This case demonstrates how our approach can be adapted to different picking methodologies, including advanced automated systems. By addressing the unique challenges of robot-based picking, we created a more balanced workflow that maximized the effectiveness of the automation investment.

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Case study: Multi-channel retail distribution

A multi-channel retailer used our optimizations to improve operational efficiency during peak seasons:

 

Challenge:

 

  • 253 orders requiring 350 picking batches
  • 6,805 total aisle visits required
  • High concentration of slow-moving inventory in prime picking locations

 

Solution:

 

  • Implemented wave optimization to create efficient batches
  • Identified and relocated dead/slow-moving inventory
  • Applied data-driven slotting recommendations for high-velocity items

 

Results:

 

  • Batches reduced from 350 to 257 (26.6% reduction)
  • Aisle visits reduced from 6,805 to 1,240 (81.8% reduction)
  • 30% improvement in Units Per Hour

 

This dramatic reduction in aisle visits translated directly to labor savings and increased throughput capacity, enabling the client to handle peak volumes more efficiently without adding resources. The multi-channel nature of this operation presented complex challenges that our integrated approach effectively addressed.

 

Implementation success factors

Our ability to drive consistent results across diverse operations stems from several key factors:

 

  • Data-driven approach: Decisions based on actual usage patterns rather than assumptions
  • Customized configuration: Solutions tailored to each client's specific operational needs
  • Minimal disruption: Implementation designed to work alongside existing operations
  • Continuous refinement: Ongoing analysis and adjustment to maintain optimal performance

 

These real-world results demonstrate the significant impact our integrated approach has on warehouse operations. For more details on the technical aspects of our solution, see our article [Inside Warehouse Optimization: Slotting & Wave Pick Techniques].

Discover how GEODIS can optimize our facilities for your warehousing needs. Get in touch with GEODIS.

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Business benefits beyond the metrics

The quantitative improvements delivered by our warehouse optimization solution translate directly into substantial business benefits for your operations.

 

Operational benefits

The most immediate benefits come from improving day-to-day warehouse operations.

 

Enhanced picking efficiency

Our approach resolves the fundamental inefficiency of warehouse picking—the excessive time spent walking between locations:

 

  • Reduced aisle visits mean pickers spend more time picking and less time walking
  • More efficient pick paths minimize unnecessary movement throughout the facility
  • Balanced workload distribution improves overall picker productivity

 

Optimized space usage

Warehouse space is a valuable resource, and our solution helps you maximize its value:

 

  • High-velocity items positioned in prime picking locations
  • Dead and slow-moving inventory relocated to less premium areas
  • More strategic use of valuable pick-front real estate

 

This ensures the most accessible warehouse space is used for the products that contribute the most to your order fulfillment operations.

 

Reduced congestion and improved flow

Beyond individual picker efficiency, our solution enhances overall warehouse flow:

 

  • Strategic distribution of high-demand products prevents bottlenecks
  • Multiple pick locations in automated environments reduce robot congestion
  • More balanced traffic patterns throughout the facility
  • Reduced congestion during peak periods and product launches

 

Workforce benefits

Our solution also delivers significant benefits for warehouse teams.

 

Improved productivity and job satisfaction

More efficient picking creates a better working environment:

 

  • Reduced walking distance decreases fatigue
  • More efficient workflows create a more satisfying work experience
  • Greater productivity leads to improved performance metrics
  • Less frustration from inefficient processes and congestion

 

These benefits contribute to a more engaged workforce and potential improvements in staff retention—crucial advantages in today's competitive labor market.

 

Optimized labor allocation

Our solution helps make the most of labor resources:

 

  • More orders processed per hour with the same workforce
  • Labor resources redirected from non-value-added travel to productive activities
  • More predictable workflows improve workforce planning
  • Enhanced ability to handle volume spikes without adding temporary labor

Discover how warehouse optimization can transform your logistics operations. Contact our team to discuss your specific needs and see how our solution can deliver measurable benefits for your business. Get in touch with GEODIS.

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Business impact

These operational and workforce benefits translate directly to business performance:

 

Reduced fulfillment costs

Efficiency gains deliver substantial productivity savings:

 

  • Greater throughput without proportional cost increases
  • Reduced need for overtime during peak periods
  • More efficient use of warehouse space
  • Labor optimization through reduced non-productive time

 

Enhanced capacity and throughput

Our solution expands order fulfillment capacities without physical expansion:

 

  • Process more orders through the same facility
  • Handle volume spikes more effectively
  • Support business growth without proportional increases in labor and space
  • Extend the useful capacity of current warehouse infrastructure

 

This enhanced capacity provides greater operational flexibility and resilience, particularly during peak periods or unexpected demand surges.

 

Improved service level performance

Ultimately, these improvements enhance your ability to meet customer expectations:

 

  • Faster order processing supports shorter delivery timeframes
  • More accurate inventory management reduces out-of-stock situations
  • Increased capacity enables consistent service level performance even during peaks
  • Greater flexibility to adapt to changing order patterns

 

By strengthening your fulfillment capabilities, our solution helps you deliver the speed, accuracy, and reliability that today's customers demand.

 

Competitive advantage

In an increasingly competitive logistics landscape, warehouse optimization makes a big difference:

 

  • Enhanced ability to meet demanding service level agreements
  • More consistent performance during challenging periods
  • Lower operating costs allow for more competitive pricing
  • Greater scalability to support business growth

 

The business benefits of our warehouse optimizations extend far beyond operational metrics. By transforming the fundamental efficiency of warehouse operations, we help you reduce costs, increase capacity, improve service levels, and build competitive advantage—all without additional cost to GEODIS clients.

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Implementation process

We use a collaborative approach that combines your data and requirements with our optimization expertise to deliver rapid results with minimal disruption.

 

Implementation process overview

Our streamlined four-step implementation process typically takes just 2-3 weeks per component:

 

  1. Data collection and analysis
     
    • Gather historical order data from you (ideally 52 weeks)
    • Analyze facility layout, storage locations, and picking zones
    • Document current picking paths and methodologies
    • Evaluate SKU characteristics and movement patterns
       
  2. Solution configuration
     
    • Optimize our algorithms to your operations
    • Rank locations based on your warehouse layout
    • Segment SKUs based on your inventory profile
    • Develop wave templates based on your requirements
       
  3. Execution and implementation
     
    • Get the open order list from your teams
    • Run our algorithms to create optimized batches
    • Send the results back to operations for implementation
    • Make recommendations for inventory placement and slotting
       
  4. Performance validation
     
    • Track key metrics like aisle visits, units per hour, and travel distance
    • Compare performance with pre-implementation baselines
    • Refine our algorithms based on real-world results
    • Identify and implement continuous improvement
       

Meeting specific client and facility requirements

We configure all slotting and waving requirements in our facilities to client needs:

 

  • Customizable business rules: We define specific rules for wave planning, including criteria for grouping orders by carrier, delivery service, requested ship date, or other business-critical factors
  • Adjustable batch sizes: Batch size parameters are tailored to match picking cart capacity, picker capabilities, and order characteristics for each operation
  • Flexible volume thresholds: For facilities requiring cartonization, volume thresholds are adjusted to align with specific packaging requirements
  • Pick zone prioritization: We define custom rules for prioritizing picking zones based on warehouse layout and operational priorities
  • Wave release scheduling: Wave release timing is configured to align with specific cut-off times, shipping schedules, and labor availability at each facility

 

Implementation requirements

Implementation requirements are minimal and use your data and our existing systems:

 

  • Historical order data (ideally 52 weeks)
  • Warehouse layout information
  • Current location assignments
  • SKU master data

 

For new clients without historical data, we can work with information from your previous providers.

 

Ongoing optimization and support

We continue to optimize your warehouse operations after initial implementation:

 

  • Weekly data refresh: The system analyzes the most recent 52 weeks of data each week
  • Regular performance reviews: We track key metrics and identify opportunities for further improvement
  • Continuous algorithm refinement: Our optimization approaches improve based on changing patterns and needs
  • Operational support: Our teams assist with questions and adjustments

 

This ongoing support ensures that our warehouse optimizations continue to deliver value as your business evolves.

 

Adaptable to diverse warehouse environments

Our warehouse optimization solution is designed to accommodate the unique characteristics of our various facilities:

 

  • Layout flexibility: Whether your warehouse uses traditional racking, automated storage and retrieval systems, or a combination of storage types, our solution adapts to your specific layout
  • Diverse picking methodologies: The solution supports multiple picking strategies including S-shape, return method, mid-point, and largest gap approaches
  • Varying facility sizes: Our approach scales effectively from our smaller distribution centers to massive fulfillment operations

 

This adaptability means we can implement our warehouse optimization solution across our network of facilities, achieving significant efficiency gains without disrupting established operations.

 

Explore our warehouse optimization series

Want to learn more about our warehouse optimization approach? Explore these in-depth articles:

 

How GEODIS can help

GEODIS provides warehouse optimization for any of your operations in our facilities. 

 

  • Quick implementation: Each component (slotting and wave optimization) takes just 2-3 weeks to implement
  • No additional cost for GEODIS clients
  • Minimal disruption to existing operations
  • Measurable results: Performance improvements visible shortly after implementation
  • Ongoing support: Regular analysis and refinement to maintain optimal performance

 

We tailor our approach to your specific operations:

 

  • Customized configuration based on your unique requirements
  • Flexible implementation that works with our existing systems
  • Regular performance reviews and continuous improvement
  • Adaptability to changing order patterns and operational needs

 

By combining strategic inventory placement with intelligent order processing, we help you reduce costs, increase capacity, and improve service levels—all with minimal disruption to ongoing operations.

 

Get in touch with GEODIS. 

Contact us

FAQs

Each component (slotting and wave optimization) typically takes just 2-3 weeks to implement in our warehouses. The entire solution can be implemented in 4-6 weeks, with benefits visible shortly after implementation.

No. Warehouse optimization is provided at no additional cost for GEODIS clients.

Our implementations typically show efficiency improvements ranging from 15% to 60%, depending on current warehouse organization. Even well-organized facilities see 15-20% gains, while less optimized operations experience more significant improvements.

No. Our solution is designed to work alongside our existing operations with minimal disruption. The system uses your current warehouse layout and picking methodologies as the foundation for optimization.

While our solution may recommend relocating some inventory based on movement patterns (particularly slow and dead movers), it doesn't require significant physical changes to warehouse infrastructure.

We need historical order data (ideally 52 weeks), warehouse layout information, current location assignments, and SKU master data. For new clients without historical data, we can work with information from previous providers.

Our system analyzes 52 weeks of rolling historical data, refreshed weekly. This continuous analysis allows the system to adapt to seasonal changes, new product introductions, and evolving order patterns, ensuring optimal performance even as conditions change.

Yes. Our solution is compatible with both traditional and automated picking environments, including facilities using Locus robots. For automated environments, we adapt our approach to address unique challenges like robot congestion.

We track key metrics like aisle visits per task, units processed per hour, task count, and orders processed per task. We compare these metrics to pre-implementation baselines to quantify the improvements delivered by our solution.

We provide continuous support including weekly data refresh, regular performance reviews, algorithm refinement based on changing patterns, and operational assistance with questions and adjustments.

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Paul Maplesden

Lead Content Strategist

Paul deeply researches logistics and supply chain topics to create helpful, informative content for our US audience. Read Paul's work in the GEODIS blog, our in-depth GEODIS Insights reports, and our case studies and white papers.
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