Central Warehouse Design (Storage, Handling, Flow & Process) for Cult.fit

Central Warehouse Design - Optimization of Space, Storage, Handling, Flow & Process

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About The Organization

Cult.fit (formerly Cure.fit or Curefit) is a health and fitness company offering digital and offline experiences across fitness, nutrition, and mental well-being. With the aim to make fitness fun and easy, cult.fit gives workouts a whole new meaning with a range of trainer-led, group workout classes. It makes workouts fun, daily food is healthy and tasty, mental fitness easy with yoga and meditation, and medical and lifestyle care hassle-free. Co-founded by Mukesh Bansal and Ankit Nagori in 2016, the company is headquartered in Bangalore, Karnataka.

Cult.fit leverages technology and data to enable people to live a healthy lifestyle and get access to healthcare at an affordable cost. It offers both online and offline experiences across fitness, nutrition, and mental well-being through its holistically integrated four verticals. While cult.fit caters to physical fitness, mind.fit is for mental well-being, eat.fit for healthy food, and care.fit looks at personalized healthcare services, including consultation and diagnostics.

OPPORTUNITY

Cult.fit was expanding at a very fast rate across the country and thus there was a need to look at the central warehouse and optimize the same to meet the growing needs.

Following are the areas that have to be worked upon or redesigned or upgraded:

Inventory Holding and Right Sizing
Space Utilization and Requirement
Storage Forecast
Material Handling Selection and Flow Design
Warehouse Processes
Warehouse Performance
Cost efficiency
To-Be design – Space forecast, Warehouse design, Resource Requirement, and CAPEX

SOLUTION

Tools & Techniques Used:

Concepting/Slotting Technique
Inventory Health Analysis
Flow Simulation
Product Portfolio Vs HU Designs
Throughput Analysis
Pareto Chart
FMEA

Warehouse Optimization Study – Process, Work flow, Systems and Material Flow
- Complete Warehouse Operations Value Stream of Curefit
- GEMBA Study of Warehouse Operations
- Through-put time study of Warehouse Operations
- Unit Economics Study
Warehouse Layout Design (Space, Storage, Material flow, Handling and Process)
- Product Rationalization
- SKU Segmentation
- Capacity Planning
- Recommended Storage estimation
- Storage – Rack & Bin Design
- Process Design
- Block layout design
- Final layout design
Automation selection based on ROI
Request for Quote Process
- Finalize all the Design specifications for Storage, Handling and for Flow
- Release BOMs
- Build RFQ document and roll out
- Lead Discussions, Negotiations and finalize Vendor
- Release Final Order
Warehouse Start-up Implementation / Stabilization

RESULTS

Cult.fit, a health and fitness company

Warehouse Designs are Optimized; By Smart Design, the current warehouse utilization of 45% is enhanced significantly to a level where the warehouse can now cater for next 2 years with the projected growth with no further investment of space.