The Sleep Company

Project Overview

The project aimed to consolidate the raw materials (RM), production, and finished goods (FG) departments under one roof to efficiently handle a wide variety of products, from small consumables and bedding items like pillows and bed covers to larger items such as fabric rolls, foams, springs, mattresses, recliners, and bed frames. This consolidation was key to meeting the rapidly growing customer demand and expectations while enhancing the overall customer experience.

Design Objectives

Streamline the material flow across RM, Production, FG, and Returns.
Maximise the storage capacity.
Improve material handling and movement.
Boost productivity and reduce labour dependency.

Our Solutions

Streamlined, unidirectional flow of man-material-machine, reducing conflicts, mix-ups, and cycle times while improving safety.
Utilised vertical storage space for all product categories, including large items like fabric rolls, foams, mattresses, recliners, and bed frames, boosting storage density and freeing up floor space for production processes.
Standardised pallets by category, ensuring racking and material handling equipment compatibility for faster, safer movement.
Designed metal cage pallets for long-length rolled mattresses and cage trolleys for cut fabric covers, replacing manual handling.
Standardised reach trucks with attachments that suit various pallet sizes, improving resource utilisation across departments.
Mechanised the production process, reducing manual labour and time while improving material and operator safety and boosting throughput.
Ergonomically designed workstations, combined with strategic planning and well-placed hygiene facilities, promote healthy working conditions and improve worker morale.
Placed clear signage for easy identification, directional guidance, and information, reducing confusion and potential risks.
Dedicated, specified, and demarcated spaces for all the equipment and activities, avoiding material contamination and operator confusion and enhancing operational productivity.