Improving warehouse productivity through optimized packaging

The challenge: Improving warehouse productivity through optimized packaging

Inter Cars Poland, after launching their e-commerce platform, encountered a significant logistical challenge within their warehouse operations. The task of selecting the appropriate carton for each shipment proved to be more complex than anticipated. Warehouse employees often chose boxes that were either too large, resulting in increased shipping costs, or too small, necessitating time-consuming repacking of goods into larger boxes. This not only drove up operational costs but also obstructed overall productivity. The challenge lies in optimizing the carton selection process to ensure cost efficiency and maintain high productivity levels in the warehouse.

Created value: Reducing shipping costs while improving productivity

By implementing ORTEC Load Optimization, we provide warehouse employees with precise information on the optimal carton for each shipment. This system considers product dimensions, allowed orientations, and stackability rules to determine the best carton size.

Expanding horizons: Tools, equipment, and more for automotive excellence

Inter Cars Poland stands as the largest importer and distributor of automotive spare parts for passenger cars and commercial vehicles in Central and Eastern Europe. Their extensive product portfolio goes beyond spare parts, encompassing garage equipment, specialized tools for servicing and maintaining vehicles, as well as motorcycle spare parts and tuning components.

With a robust logistical infrastructure, Inter Cars operates as a highly specialized logistics company, managing and financing the seamless flow of goods from over 500 manufacturers—primarily from the European Union—to local distributors. These distributors, organized as branches, ensure timely delivery to end users, including garages, retail shops, and individual customers.

Inter Cars' operations are anchored by a central warehouse located near Warsaw, which serves as the hub for their expansive distribution network.

The primary goal of this project was to enable Inter Cars Poland to leverage the advanced optimization capabilities of the ORTEC Load Optimization (OLO) solution to enhance their packaging performance. OLO integrates seamlessly with the already implemented Inter Cars Linker solution, which is used for palletization, becoming an integral part of the daily shipment planning process.

Since its implementation, carton usage per order has decreased by 1.5%, resulting in substantial operational benefits. This reduction equals approximately 1,200 fewer packages and saves around 20 pallet places per month. "In the coming future, we anticipate even greater savings as the system continues to evolve and adapt to our growing needs”. This optimization not only reduces material usage but also better utilizes transport space, driving significant cost savings and increased efficiency.

Enhancing employee efficiency and streamlining warehouse workflow

The implementation of ORTEC Load Optimization has revolutionized the packaging process at Inter Cars Poland, „delivering significant improvements in employee efficiency and warehouse workflow”. By automating the carton selection process, the system eliminates the need for employees to manually decide on packaging sizes, allowing them to focus on faster, more accurate packing. This not only saves time but also reduces errors, ensuring shipments are prepared efficiently. Furthermore, optimized packing enhances the overall workflow by minimizing delays during loading and transport, contributing to smoother warehouse operations and improved productivity across the board.

Adapting to evolving logistics demands

As Inter Cars Poland’s e-commerce platform continues to grow, the demands on their logistics and warehousing operations are also increasing. The ORTEC Load Optimization system plays a key role in addressing these evolving challenges by further enhancing the packing process. "With the dynamic growth of e-commerce, ORTEC Load Optimization helps us streamline packing and adapt to changing requirements," says Mateusz Utnicki, Logistics Development Manager. "This ensures efficient management of resources and warehouse space, which is vital for maintaining high-quality customer service." As these demands rise, ORTEC’s scalable system ensures Inter Cars can continue to meet them while maintaining operational efficiency.

The benefits: 

• Significant cost savings

• Preparedness for future e-commerce growth