Rafa Merino
Warehouse design
Comprehensive transformation of the client's warehouse, transforming logistics operations into an engine of efficiency and growth.
We began with a thorough analysis of processes and data: actual movements, demand patterns, occupancy levels, operational areas, and flow dynamics. This in-depth view allowed us to identify the truly relevant information for building a robust and scalable solution.
With this, we define the new material flows, the inventory location strategy, and an optimized layout that maximizes space, reduces movement, and improves productivity.
In addition, we redesigned the picking and shipping process, introducing improvements that streamline order preparation and enhance the quality of service.
Finally, we incorporated digitization tools at key stages of the operation, providing visibility, control and real-time decision-making capabilities.
The result: a modern, efficient warehouse, ready to support the growth of the business in the coming years.
Supply of components to the factory
We assisted a renewable energy manufacturer in a key challenge for its growth: completely redesigning the material supply system between its central warehouse and the assembly lines. The complexity of its component catalog, the high variability in production demand, and the lack of visibility into the flows were creating bottlenecks that directly impacted workshop productivity.
Our team analyzed every stage of the process in detail—from needs planning and kit preparation to internal transport and final delivery to the assembly stations—identifying inefficiencies, critical coordination points, and automation opportunities. Based on this analysis, we designed a comprehensive solution based on lean flow principles, dynamic replenishment, and digitalization of operations.
The implementation of the new model allowed for the consolidation of a stable, agile supply chain, fully synchronized with production. Operators began receiving the exact materials at the precise moment, eliminating unnecessary movement and preventing inventory buildup on the factory floor. Furthermore, the digitization of movements and real-time monitoring provided complete process traceability.
Thanks to this project:
We eliminate stockouts, ensuring the continuity of each assembly order.
We significantly reduced inventory levels, freeing up space, capital, and operational capacity.
We increase logistics productivity by optimizing internal routes, picking times, and locations.
We increased the reliability of the supply, with standardized processes and early warning systems.
This case demonstrates how well-designed logistics can become a decisive competitive advantage. Our goal is always the same: to transform materials management so our customers can focus on what matters most—manufacturing more, better, and more profitably.
Implementation of Manufacturing Cells
We have helped organizations take a qualitative leap in their productive performance by implementing manufacturing cells designed to create continuous, stable and highly efficient flows.
This type of project involves a complete reorganization of the factory, aimed at eliminating interruptions, reducing downtime, and synchronizing operations. The result:
Lead time significantly reduced
Lower and better controlled inventories
Higher level of customer service, thanks to more agile and reliable processes
We apply Lean principles to production, planning, and logistics to transform every process into a simpler, faster, and more robust system. From flow design to plant implementation, we support our clients to ensure sustainable improvement that translates into a real competitive advantage.
Redesign of the operations of a manufacturer in the automotive sector
In this project we accompanied an automotive manufacturer in the transformation of its operations to boost productivity, reduce costs and improve service quality.
The process began with a comprehensive analysis using Value Stream Mapping (VSM), a key tool for visualizing the actual flow of materials and identifying bottlenecks and high-impact improvement opportunities. Thanks to this operational overview, we prioritized specific actions to address critical inefficiencies.
Next, we implemented a progressive improvement plan based on the PDCA (Plan-Do-Check-Act) methodology, ensuring a controlled, measurable, and sustainable implementation over time. Each iteration generated tangible progress aligned with the client's strategic objectives.
The result: more agile, efficient operations, better prepared to respond to the demands of a sector as dynamic as the automotive industry.
Warehouse reference placement strategy
The way in which references are organized within the warehouse can make the difference between a smooth shipping process and one full of inefficiencies.
We conduct in-depth analyses of our clients' order books to understand how their products actually perform. By studying the correlation index between product references, we identify purchasing patterns, natural associations, and picking sequences that allow us to redesign warehouse logic from a performance-oriented perspective.
The result: an optimized location strategy that minimizes errors, streamlines order picking, and ensures FIFO compliance. A solution that not only improves warehouse productivity but also makes every operation more intuitive, safe, and efficient.
Reduction of Supply Stock
We optimize your inventory levels so you only have the stock you really need… and always on time.
In our Stock Reduction projects, we analyze and redesign the replenishment system for each quality and reference, ensuring maximum availability without generating additional costs or unnecessary immobilized assets.
We implement dynamic stock levels, continuously adjusted according to demand forecasts and customer service objectives. Furthermore, we integrate your suppliers' actual performance to define more reliable, agile, and efficient replenishment plans.
The result:
Less immobilized stock
Higher turnover
Higher level of service
A supply system aligned with your business
Sales forecast
In a sales forecasting project, data must be transformed into information that supports operational and strategic decisions. We thoroughly analyze demand patterns and all the variables that influence them. We apply advanced modeling techniques and cutting-edge algorithms, from ARIMA and Holt-Winters to neural networks such as univariate and multivariate CNNs, and LSTM.
Our approach combines multiple models to maximize prediction accuracy. The results are presented transparently: through charts comparing algorithms and box plots reflecting the mean and variability of predictions, enabling our clients to make confident, informed decisions.
With our methodology, sales forecasting ceases to be an estimate and becomes a strategic tool that drives the efficiency and profitability of your logistics operation.
Dynamic establishment of stock levels and replenishment
We transform inventory management with a dynamic and personalized approach. We adjust safety stock levels according to the actual needs of each product, improving service levels while reducing tied-up capital.
Furthermore, our replenishment orders are precisely planned: we analyze recent consumption, identify trends, and consider seasonality, ensuring that each order arrives at the right time, neither too early nor too late.
The result: more efficient inventories, more agile operations, and decisions based on real data, not estimates.
