Client:
A $200 million consumer packaged goods (CPG) manufacturer with U.S.-based production and international distribution,
Challenge:
The company was facing operational bottlenecks in its warehousing and logistics functions and experienced an abrupt departure of its Transportation & Logistics Manager. With a 3–6 month hiring timeline anticipated, they faced both a leadership gap and a missed opportunity to address known inefficiencies in shipping, receiving, and warehouse layout.
Additionally, the company saw potential to optimize its global distribution network—particularly through improved 3PL partner selection in non-U.S. regions and improvement of freight-related costs and warehouse productivity.
Labor shortages, inefficient workflows, and disconnected systems added complexity to an already strained operation.
Strategic Objectives:
- Provide interim leadership coverage to stabilize transportation and logistics functions.
- Evaluate and optimize the U.S. warehouse layout and material handling processes.
- Implement process improvements and system enhancements to reduce cost and improve data visibility.
- Assess and improve performance across both domestic and international logistics networks.
- Generate measurable savings and process gains that would persist beyond the interim role.
Approach:
Waypost placed an experienced logistics leader into the interim role within two weeks of engagement. The Advisor immediately conducted a deep-dive into current-state roles, responsibilities, KPIs, and warehouse layout.
Key activities:
- Mapping inbound and outbound material flows, identifying time and space inefficiencies.
- Auditing U.S. and international transportation costs and proposing spend reduction strategies.
- Collaborating with customers to improve how they package inbound materials for easier, faster receiving.
- Recommending process changes such as barcode scanning for improved ERP integration and tracking.
- Establish warehouse metrics to monitor productivity and improve labor management.
- Supporting the implementation of live carrier tracking software to maximize parcel revenue opportunities.
- Leveraging procurement processes to reduce global warehouse rental costs.
Key Steps:
- Onboarding into interim leadership role with cross-functional exposure
- U.S. and international freight audit and savings identification
- Warehouse flow and process re-engineering
- System use assessment and ERP/parcel system integration
- Customer collaboration to reduce claim and receiving friction
Assessment Areas:
- Warehouse layout and handling costs
- Transportation network structure and spend
- ERP usage gaps in logistics and receiving
- Customer-side shipping practices
- 3PL selection and contract value
Tools and Methodologies:
- Freight spend and flow analysis
- Layout redesign and handling cost modeling
- Barcode scanning and ERP data capture integration
- KPI development for warehouse and transportation teams
- Interim role documentation and transition readiness
Deliverables:
- $45K+ annual savings via warehouse reconfiguration
- Improved receiving process and reduced customer claims
- Implementation of barcoding for ERP system usage
- Productivity tracking via warehouse metrics
- Procurement-driven reduction in global warehouse rental rates
- Long-term logistics improvement roadmap and interim role documentation
Conclusion:
The Waypost interim leader did more than maintain continuity—they unlocked meaningful operational improvements across both domestic and international logistics. Warehouse efficiency, transportation cost control, system visibility, and labor productivity were all improved under their leadership.
“We achieved measurable cost savings and smoother operations, even during a leadership transition.”