Zone-level inefficiencies
Ambient, chilled and frozen areas ran in silos yet shared the same slotting and replenishment problems. SKUs were rarely positioned for efficient access, slowing pick rates.
Case Studies / Food & Beverage
Efficiency in Food Distribution with WareBee
A leading UK food and beverage brand operating a national distribution centre that supplies thousands of outlets daily, across ambient, chilled and frozen zones.
- 22%Less walking distance per picker
- 12%Higher picking productivity (lines/hour)
- 18%More picks per tote (shipment density)
- 15%Fewer replenishment tasks
The approach
WareBee deployed its digital twin to replicate the facility across every zone. Using SKU velocity and frequency analysis, affinity groupings and labour simulations, the team surfaced hidden inefficiencies and tested improvements in slotting, replenishment and tote fill before any change touched the floor.
What we found
The inefficiencies hiding in plain sight.
Underused assets
Containers and roll cages were underutilised, with picking density well below potential, and tote usage lacked optimisation logic, raising handling effort per shipment.
Labour and ergonomics
Congested aisles and poorly sequenced totes slowed navigation, and workforce planning missed zone-specific peaks: overstaffed in one zone, bottlenecked in another.
Tote and shipping
Tote fill density was inconsistent, and heavy items were sometimes stacked above light ones, increasing rework and damage risk in transport.
Replenishment and picking
High-velocity SKUs in small locations forced frequent replenishment, while low-velocity SKUs held prime real estate in high-turnover zones, lengthening pick routes.
What we did
Changes tested in the twin, then made on the floor.
Velocity-based slotting per zone
Re-slotted fast movers in ambient, chilled and frozen areas to minimise walking and speed picks.
Ergonomic improvements
Moved high-frequency SKUs to waist level, cutting fatigue and improving safety.
Tote and dolly optimisation
Improved tote fill sequencing and dolly-board routes, maximising picks per tote with heavy-to-light stacking.
Continuous monitoring
Automated alerts for slot degradation, route friction and high-variance locations.
Operational benchmarking
Quantified baseline performance and simulated improvements before committing physical changes.
Simulation-driven labour planning
Forecast zone-specific demand and matched staffing to store dispatch waves.
The outcome
WareBee delivered ROI within three months: travel per picker down 22%, picking productivity up 12% across all zones, shipment density up 18% and 15% fewer replenishment tasks, with real-time visibility that supports proactive decisions every shift.
Why WareBee
In food distribution every pick must be fast and accurate. WareBee's zone-aware simulations, tote optimisation and ergonomic improvements lifted pick productivity, maximised tote fill and streamlined labour, all while improving employee safety and on-time delivery quality.
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