CASE STUDIES
Warehouse Efficiency Optimisation
At PainKiller Logistics Consulting, warehouse optimisation projects have consistently delivered measurable cost savings. On average, across multiple warehouse improvement programmes, we reduced picking times by 18%, improved shift productivity by 12%, and cut overall warehouse labour costs by 8–10%. These improvements were achieved through smarter slotting strategies, redesigned picking routes, and better space utilisation — proven methods that reduce costs and improve service levels.
Inventory Accuracy & Stock Control
Inventory accuracy is often the hidden drain on logistics performance. By implementing structured cycle counting, data-led demand forecasting, and automated discrepancy alerts, we helped businesses improve stock accuracy to 98–99%. On average, this reduced stockouts by 15%, cut excess stock holding by 12%, and freed up tens of thousands of pounds in working capital. Strong inventory control is one of the fastest ways to stabilise cash flow and customer service simultaneously.
Transport & Delivery Planning
Transport is one of the largest costs in supply chain operations — and one of the most overlooked for savings. Our logistics transport planning approach delivered on average a 10–14% reduction in mileage and a 9% improvement in on-time deliveries, by introducing load consolidation, smarter routing, and demand-driven scheduling. This not only reduced fuel spend and CO₂ emissions but also strengthened service levels to customers.
Headcount & Workforce Planning
Labour inefficiency can erode margins quickly. Using proactive workforce planning dashboards, we have helped operations align labour to actual demand, reducing overtime by an average of 22% while also cutting agency reliance by 17%. Over a 6-month period, one project avoided more than £150,000 in unnecessary labour spend while maintaining pick rate performance. The outcome: leaner operations and happier teams who no longer feel constantly over- or under-staffed.
Supply Chain Visibility & Reporting
Lack of real-time data visibility often prevents logistics leaders from making effective decisions. By introducing integrated reporting dashboards, our projects delivered a 30% faster decision-making cycle and reduced planning errors by 25%. Across engagements, we’ve seen businesses move from firefighting daily issues to proactively steering operations with clarity, driving both resilience and growth. Visibility isn’t just about data — it’s about giving leaders control of their supply chain.
New Store & Market Openings
Scaling into new stores or regions without logistics discipline creates chaos. PainKiller Consulting has developed structured New Store Opening (NSO) playbooks that ensured 100% stock availability on launch day. Across more than a dozen NSO support projects, we achieved zero delays in go-live, streamlined supplier deliveries, and prevented last-minute logistics failures. On average, this avoided launch overruns worth £25,000–£50,000 per site while keeping expansion plans on track.