Lupin

Project Overview

Lupin Limited is a prominent global pharmaceutical manufacturer headquartered in India. To strengthen its logistics capabilities for the Maharashtra region, Lupin Limited aims to establish a centralised warehouse distribution operation in Bhiwandi, Maharashtra.

Business Challenge

Establish a pan India distribution centre to manage projected volumes over the next 5-6 years
Ensure seamless man-material-equipment flow, fostering healthy working conditions and scalability.
Identify the most efficient storage, put away, picking, and sorting strategies for SKUs in both CWH and CFA operations.
Determine the optimal balance between human efforts and mechanisation

Our Solutions

Designed a unilateral flow for man and material to streamline operations.
Intensified cube storage optimisation by providing a column-supported mezzanine system (CSM) with perforated gratings catwalk to increase air changes in the aisle.
Introduced long-span shelving system (LSS) for flexible storage binning of SKUs.
Implemented the use of a selective pallet racking system for bulk storage of SKUs.
Integrated mechanisation with motorised conveyors for vertical material transfer, reducing human intervention.
Recommended handheld terminals for picking to reduce strain and fatigue.
Ensured seamless integration of physical processes with the Warehouse Management System (WMS).
Boosted productivity with ergonomic, durable checking and packing stations, optimal LUX levels, and enhanced surveillance.