03/26/2025

Manufacturing Logistics Case Study: Inbound Materials Optimization

GEODIS optimized 385,000 square feet of warehouse space and implemented 4-hour inventory replenishment cycles for a marine engine manufacturer.

Manufacturing operations rely on precise timing and logistics. When components aren't available at the right time, in the right place, and in the right quantity, production lines experience costly disruptions. A leading marine engine manufacturer turned to GEODIS to create a comprehensive logistics solution that would support their manufacturing operations while optimizing their inventory management and distribution.

Key takeaways

 

  • Strategic warehouse management in two locations totaling 385,000 square feet ensured a seamless supply of components for manufacturing
  • We supported optimal production flow and minimized disruptions with a 4-hour factory replenishment cycle
  • Our comprehensive return process improved our client's efficiency through tracking and refurbishment
  • Real-time inventory tracking enhanced supply chain visibility across our client's manufacturing and distribution operations

Facts about our manufacturing client

 

  • Leading marine engine manufacturer specializing in outboard motors
  • Key manufacturing and distribution operations in two major locations in the U.S. 
  • Complex component supply chain requiring precise inventory management
  • Comprehensive returnable packaging program requiring tracking and refurbishment

 

Background with our manufacturing client

Our client needed a strategic logistics partner to optimize their manufacturing support operations. Their production facilities required efficient warehousing, precise inventory management, and timely component delivery for optimal production schedules. Additionally, they needed support for their distribution operations, where finished engines manufactured overseas needed to be received, stored, fulfilled, and distributed.

 

 

Challenges for our manufacturing client

Our client had several complex logistics challenges that impacted their manufacturing and distribution capabilities:

 

  • Parts storage management: Needed efficient organization and quick retrieval of thousands of manufacturing components
  • Factory replenishment: Required timely and accurate delivery of materials to support production schedules
  • Finished engine crate handling: Needed to streamline returnable crate inventory, cleaning, and refurbishment
  • Distribution operations: Required optimization of logistics for both component supply and finished product shipment
  • Inventory visibility: Needed real-time tracking of parts, returnable packaging, and finished goods
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Manufacturing solution and approach

GEODIS introduced a comprehensive logistics solution that met our client's manufacturing support and distribution needs:

 

  • Management of a 235,000-square-foot facility dedicated to manufacturing support operations
  • Operation of a 150,000-square-foot finished engine distribution warehouse, handling overseas-manufactured engines
  • Implementation of 24/5 operations with three shifts to ensure seamless material flow and factory support
  • Development of real-time inventory management and reporting systems to enhance supply chain visibility

 

Our approach included multiple integrated service components:

 

Manufacturing parts storage and factory replenishment

 

  • Received, stored, and reported parts receipts to the client's plant with a 5 days a week, 3 shifts schedule
  • Replenished factory parts inventory every 4 hours using an automated EDI system
  • Managed printed label scans for parts going to the plant through the client's system
  • Assisted with the inspection of incoming parts using the client's designated inspection service

 

Parts dunnage handling and repackaging

 

  • Checked for leftover parts before processing empty dunnage
  • Sorted and ensured proper configurations for supplier returns
  • Coordinated shipping of dunnage to designated vendors via client-specified carriers

 

Finished engine crate management

 

  • Scanned and tracked returnable engine crates through the client's system
  • Inventoried, cleaned, and refurbished crates
  • Managed inventory and shipment of crates to external cleaning vendors
  • Reported monthly inventory of crate components to the client

 

Returned engine management

 

  • Received, inventoried, and reported serial numbers of returned engines
  • Managed shipments of returned engines based on the client's specified disposition

 

Storage solutions and value-added services

 

  • Stored critical assets for various departments, including engineering and R&D components, engine cores, and specialty machinery
  • Provided internal machining tray cleaning and handling
  • Assisted with quality review of parts before going to the manufacturing plant
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Manufacturing client results

Our logistics solution delivered significant improvements to our client's operations and supply chain efficiency:

 

  • Improved factory efficiency with 4-hour inventory replenishment, ensuring continuous production
  • Optimized 385,000 square feet of warehouse space across multiple locations
  • Reduced operational downtime through real-time tracking and reporting
  • Enhanced supply chain visibility for parts, engines, and returnable assets

 

Our integrated approach to manufacturing support logistics and distribution created a seamless flow of materials and finished goods. This allowed our client to focus on their core manufacturing operations while GEODIS handled the complex logistics requirements.

How GEODIS can help

GEODIS is one of the biggest logistics providers in the U.S. and around the world. Here's what you can expect when you collaborate with us on your manufacturing logistics:

 

  • Seamless integration with your manufacturing operations through strategic warehouse locations and customized logistics processes
  • Real-time inventory management providing complete visibility across your supply chain
  • Efficient factory replenishment ensuring optimal production schedules
  • Comprehensive returnable asset management reducing your costs
  • Value-added services including quality management, kitting, and parts preparation
  • Dedicated account teams that understand your manufacturing requirements
  • Technology-driven solutions for tracking, reporting, and continuous improvement

 

Optimize your manufacturing logistics to drive production efficiency and reduce costs. Get in touch with GEODIS to discover how we can enhance your manufacturing support operations.

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