SAP EWM Implementation for New Build Automated CPG Distribution Centre at La Doria Ltd
Using SAP Extended Warehouse Management (EWM) and Material Flow Systems (MFS) to aid UK growth and sustainability for LDH (La Doria) Ltd - the leading own-label supplier (CPG) of canned products and other ambient foods to the major UK supermarkets.
Key Areas: SAP Extended Warehouse Management (EWM), Consumer Goods, Warehouse Automation, Mobile Technology and Material Flow Systems (MFS).
Introduction
Rocket Consulting partnered with La Doria Ltd to bring our expertise in SAP EWM, consumer goods, warehouse automation, mobile technology and material flow systems to their new distribution centre in Suffolk. The warehouse is highly automated, benefitting from a Swisslog ASRS (Automated Storage & Retrieval System), high bay cranes, monorails, automated checks (pallet structure) and pallet wrappers. The facility is a true state-of-the-art distribution centre with an impressive operating capacity of 45,000 pallets of ambient storage and a daily output of over 2000 pallets per day.
The Challenge
La Doria were an existing SAP Business Suite (SAP ECC) user and were keen to retain the benefits of an integrated SAP landscape and selected one of Rocket Consulting’s specialities, the SAP Extended Warehouse Management (SAP EWM) platform, to control the entire operation at the new distribution centre.
La Doria required a SAP consulting partner who could bring valuable expertise, knowledge and experience in supply chain processes, SAP systems and integrating complex warehouse automation systems with SAP EWM to enhance operational efficiency and scalability. Rocket Consulting was the obvious choice.
The key performance indicators in this integration project were:
- Seamless integration of advanced warehouse automation technology like ASRS and mobile devices with SAP EWM.
- Provision of end-to-end project management, including coordination with the automation provider Swisslog.
- Support La Doria’s growth and sustainability strategy by delivering a future-proof, scalable solution that enhanced throughput, storage capacity and visibility.
Our Solution and Approach to SAP EWM Implementation at La Doria
Rocket was responsible for the full lifecycle of SAP EWM in the new distribution centre, orchestrated using the Rocket Mission Control Methodology for SAP supply chain and technology intensive projects.
Project management was critical to the success with such an intensive programme. Close coordination and collaboration with the warehouse automation provider Swisslog was a key success factor throughout automation integration and to ensure the Key Operational Performance Targets were both met and sustainable.
So how did it work?
Rocket led the way in several core elements of the project, including:
- Integrated SAP EWM Solution
- Successful Warehouse Automation Integration
- Enhanced Operational Efficiency
- Project Management Excellence
- Customised SAP EWM Training and Support for La Doria colleagues
- Sustainability and Future-Proof Design
- Client Trust and Strong Partnership
“Communication and visibility were key. Regular conversations, transparent project plans and alignment to the strategic objectives driving the project forward were what made this development a success.”
Helping the LA Doria team quickly adapt their existing SAP warehouse management understanding was a huge benefit to the people involved. Rocket’s SAP EWM Overview Training was quickly deployed to accelerate understanding of SAP EWM within La Doria’s team.
Designing the supply chain and warehouse processes and future ways of working was achieved during the business blueprint design phase with the help of Rocket Prototype & Demo Landscape that allowed process owners to quickly understand how things would work in the new SAP EWM platform. This increased understanding of SAP EWM integration paved the way for a successful project.
Rocket’s expertise in SAP EWM warehouse automation and integration was used to meet an extensive scope, including the following highlights:
- Goods Receiving Palletised and Slip Sheet Goods
- Production Integration
- Kitting
- Value Added Services
- Picking, Packing, Staging, Loading
- Batch Management
- Quality Inspection
- Yard Management
Using Mobile Technology as part of the SAP EWM Process
The project also included fully integrated mobile execution utilising Honeywell CK75 handheld devices for the 25 mobile workers supporting the receiving and final despatch processes. Mobile technology was successfully deployed by Rocket as a turnkey SAP mobility solution based on the native SAP EWM RF Framework and ITS mobile.
The Result - Business Outcomes
When looking back to those initial strategic project objectives of increased throughput, increased storage capacity and rationalised operating costs, the partnership between Rocket and LDH La Doria has succeeded. Crucially, La Doria will keep on succeeding, due to the ability to monitor key performance indicators at both a macro and micro level with complete visibility. A complete digital platform allows for full analysis, and decisions can be made based on the right information and in real time, to consistently meet targets.
“It is true testament to the team's commitment and original top-down approach. LDH (La Doria) Ltd has now entered a new era of operational visibility and control, facilitated by sustainable and efficient automated warehouse processes to drive growth. They have developed systems and processes that support in excess of three mission movements per year in a cost effective and efficient manner via highly automated and innovative technology. This has been achieved in partnership with Rocket, aided by their knowledge of the consumer goods industry, warehouse automation with SAP and Material Flow Systems.
Simply put, this approach means that retailers get what they want, when they want it. And so do customers.”
Sustainability was also a key driver for the project, and in 2021 year a ‘very good’ status was achieved in BREEAM.
Key success criteria of the new-build DC were achieved:
- Capacity to handle in excess of 3m pallet movements per annum
- Integrated design with low total cost of ownership
- All business logic in SAP EWM, one controlling system
- Harnessing state of the art solutions
- Remaining on the SAP roadmap
- Brexit Ready design
This case study demonstrates the value of Rocket's deep expertise in supply chain, SAP systems expertise and collaborative project management methodology, which resulted in improved operational control, reduced costs and a robust platform for future innovation.
LDH (La Doria) Ltd is not stopping here either. With a solid footprint of an automated warehouse thanks to Rocket’s integration assistance, they can look to the future and the next steps of innovation. As Mark Anson says, “we’re moving into the future now.”
"In dealing with Rocket I took great comfort in that they understood my industry and my business instantly. I felt that Rocket listened and were experts in their business understanding, speaking my language, taking the time to understand the goals and business outcomes I needed to achieve. Even before we made our formal partner selection, Rocket were very willing to go the extra mile to help, they have become a trusted sounding board.
Rocket have a mature approach to multi-vendor projects and very strong warehouse automation knowledge. Their methodology helped us establish a clearly defined and effective collaboration between Rocket as our EWM partner and our automation provider Swisslog.
Since starting the project in July, Rocket have lived up to their promises, having put in place a strong, experienced team who are very aligned to the ‘Rocket’ ways of working that we expected from the pre-sales engagements with them. The Blueprint workshops are running well, to a very good level of detail and the consultants are all extremely knowledgeable.”
- Mark Anson, IT Director, LDH (La Doria) Ltd
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