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On time, in full: The Wrekin Way

In today’s competitive marketplace, operational efficiency isn’t just a buzzword – it’s a necessity. Delivering on time and in full (OTIF) requires continuous improvements in logistics and purchasing strategies, leading to increased profitability and a more reliable customer experience. Steve O’Brien, Operations Director, explains how seemingly small adjustments in operations can drive substantial growth, proving that marginal improvements can make a monumental difference, making operations safer, better and faster.

Warehouse

Right people, right roles – leveraging expertise

One of our key transformations has been ensuring that procurement is managed by those with deep product and supplier knowledge. The traditional model of onboarding and training an external candidate with limited industry understanding can take months - time many businesses cannot afford to lose. Instead, we prioritised internal expertise, ensuring that key people are in the most suitable roles to their strengths. This understanding can streamline the procurement process, making sure that the right products are bought at the right time of year.

Team members with warehouse experience are now actively involved in procurement decisions, applying their insight into seasonal demand patterns to refine stock ordering. This ensures that we hold the right stock levels at the right time, mitigating the risks of overstocking or shortages. The result? Improved profit, reduced waste, a more responsive supply chain and a procurement process that is agile and responsive.

Warehouse optimisation: maximising efficiency

Warehouse operations are the backbone of an efficient supply chain, yet many businesses overlook small, practical improvements that can yield significant gains. We have overhauled our warehouse layout, prioritising high-demand stock in accessible areas, reducing unnecessary movement. This simple yet effective change has significantly improved order fulfilment speed, minimising pick and pack times and reduced operational strain. The logic is simple – less movement means faster processing, which ultimately leads to increased capacity and greater profitability.

Inbound logistics have also been refined to ensure that goods arriving from suppliers move seamlessly onto outbound shipments. We introduced a more fluid inbound logistics process. Instead of offloading stock into storage only to retrieve it later, many items now move directly from supplier deliveries into outbound dispatch where feasible. This approach has streamlined inventory management, lowered handling costs and improved overall efficiency.

Yard

Harnessing data for smarter decision making

The ability to track supplier performance and monitor key logistics has been instrumental in our success. By leveraging real time data, the team has pinpointed inefficiencies and introduced targeted improvements that have propelled OTIF rates above 98%.

One of the most significant advancements has been reducing lead times from five days to as little as two-three days. Additionally, order input processing times have been reduced from six hours to under five minutes. These refinements demonstrate that small, strategic changes can drive significant improvements in responsiveness and reliability.

Foundry

Eliminating disruptions: no more stocktake downtime

Stocktakes have traditionally been a necessary but disruptive part of warehouse operations, often resulting in lost selling days. However, we tackled this challenge by implementing rolling stock audits, ensuring that inventory levels remain accurate without interrupting daily workflow.

This shift has reclaimed additional selling days per year, time that directly translates into increased revenue opportunities. The traditional ‘shut down and count’ approach is arguably outdated, and a commitment to continuous accuracy should become an adopted standard.

Creating a new industry standard

Our approach to operational efficiency doesn’t just benefit its own business ambitions but sets industry standards. Making efficiency the norm and continuously refining processes, we provide service levels that remain unmatched and unrivalled.

A commitment to shorter lead times and high OTIF accuracy isn’t just an internal goal. It is a marker of excellence that enhances customer experience and strengthens competitive positioning.

The results speak for themselves – increased stock availability, record-breaking sales months and a more responsive, agile supply chain. By focusing on incremental improvements, we created a system where efficiency, profitability and customer satisfaction go hand in hand.

The key takeaway? Operational excellence isn’t achieved overnight, but through a relentless pursuit of marginal gains that, over time, redefine what’s previously been possible. This provides a competitive edge and is the difference between following industry best practices and leading them.

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