Borosil

Project Overview

Borosil Ltd., a renowned consumer and life sciences glassware name, began its journey as an Industrial and Engineering Apparatus company. To meet growing demand and increased manufacturing capacity, the company planned a state-of-the-art warehouse adjacent to its manufacturing plant in Jaipur.

Business Challenge

Ensure efficient transfer of semi-finished goods (SFG) and finished goods (FG) from the adjacent manufacturing plant to the warehouse.
Streamline the inbound movement and handling of SFG, FG, and packing materials (PM) while preventing mix-ups.
Select and design an optimal storage mix to accommodate SFG, FG, and PM under one roof.
Manage the return of picked SFG back to the factory.
Enhance picking, sorting, and dispatch processes.
Alleviate congestion in the staging and pack-and-hold areas.

Our Solutions

Implemented an inter-facility motorised conveyor system integrated with automated sorting technology to transport materials to the warehouse while segregating them by type and designated storage zones.
Designed custom storage solutions for specific material needs, including a pallet shuttle system for SFG, selective pallet racking and multi-tier shelving for FG, and dedicated shelving for PM.
Developed unidirectional, streamlined workflows for SFG, FG, and PM, ensuring material segregation, minimising contamination risks, and improving operational productivity.
Strategically aligned the conveyor system with shelving levels to enable synchronised operations, significantly enhancing picking efficiency.
Engineered an automated sorter system to facilitate route-specific segregation of FG.
Utilised the unused height above the docks by designing a dedicated mezzanine pack-and-hold area, maximising space efficiency and functionality.

Coign’s Impact

Optimised storage capacity through appropriate storage mix based on product types, inbound/outbound patterns, and volumes.
Enhanced productivity in put-away, picking, and sorting operations.
Minimised material handling, contamination risks, and product damage.
Improved order fulfilment rates and accuracy.
Eliminated congestion in processing and staging areas, preventing delays and errors.