Bazaar Kolkata

Project Overview

Currently, BRL serves its 120 in-house stores. Driven by a vision to establish a strong physical presence across the Eastern Region of India, BRL plans to expand its reach to 200+ stores by 2026 in West Bengal, Uttar Pradesh, Bihar, Jharkhand, Tripura, Assam, and Odisha from its 1,57,000 sq. ft. central distribution centre.

Business Challenge

Design a central warehouse that accommodates over 400,000 pieces of fresh inventory every day.
Develop the ideal strategies for put-away, storage, picking, and sorting to handle SKUs.
Establish the optimal mix of manual labour, mechanisation, and automation.
Ensure seamless man-material-equipment flow, foster healthy working conditions, and ensure scalability.

Our Solutions

Factored scalability into the storage system design to optimally accommodate more than 40 lakh pieces of inventory per day.
Designed unilateral flow for man and material.
Maximised cube storage capacity with column-supported mezzanines and multi-tier shelving systems, incorporating standard storage bins and meiser gratings catwalks to improve aisle ventilation and facilitate the use of hand pallet trucks.
Integrated automation to reduce manual intervention and increase the capacity to serve more stores through:
- Handheld Terminals for Picking: Reduced operator strain and fatigue.
- Lifts and Motorised Inclined Conveyors: Enabled seamless vertical movement of SKUs for inbound and outbound operations, improving order processing speeds.
- Dynamic Sorting Operations: Destination-wise automated sorting using swivel wheel sorters, boosting sorting productivity.
Aligned physical processes and the Warehouse Management System (WMS) seamlessly.
Enhanced workforce efficiency with ergonomically designed checking and packing stations, optimised LUX levels, and stringent surveillance across all operational levels.
Strategically segregated and aligned inward and outward processing stations across multiple levels to streamline workflowsm