Case Study: Transforming Ironman 4×4 distribution centre layout & operations
Table of Contents
Ironman 4×4
Ironman 4×4 specialises in the design and manufacture of off-road vehicle accessories catering to the recreational, commercial, and military sectors.
Their product range includes suspension systems, storage solutions, protection gear, recovery equipment, and a variety of accessories essential for off-roading, including camping equipment, lighting, and power systems. Ironman 4×4 operates on a global scale to serve the off-road community.
“Extolla’s expertise has helped redesign our warehouse layout and its operations, setting Ironman 4×4 up for long-term success.”
Chris Sharpe, GM Supply Chain & Procurement
What challenges did Ironman 4×4 face?
Ironman faced multiple challenges in their supply chain and warehouse operations that impacted efficiency and scalability.
Lack of storage
Their distribution centre (DC) experienced a lack of storage, which was exacerbated by inefficient inventory handling due to the diversity in product sizes and shapes. This inefficiency not only affected space utilisation but also complicated inventory management.
Technology and operational support
With ongoing and anticipated growth over the next 3-5 years, the DC needed to expand, necessitating optimisation of the current operation. To address these issues, Ironman 4×4’s new ERP and Warehouse Management System (WMS) module required significant implementation and transitional support to ensure a smooth transition and effective use of the new design and technology.
Discovery phase
- Thorough analysis to fully understand and assess Ironman 4×4’s needs.
DC design
- Utilising analytics and data, Extolla established current and future volume metrics, projecting over the design period required by Ironman 4×4.
- Developed a design to increase and optimise DC capacity while aligning with 2-3 years of growth projections, advising against overinvesting with a 5 year plan.
Material flows, safety and racking solutions
- Enhanced material flows by implementing dedicated inbound packing areas, cross-docking strategies, engineering racking and safety requirements.
- Facilitated the RFP process and implementation of a tailored racking solution.
Technology and operational support
- Extolla supported the implementation of the ERP/WMS, aiding Ironman’s transition from manual, paper-based operations to an efficient RF environment.
What outcomes did Ironman 4×4 achieve?
As a result of partnering with Extolla, Ironman 4×4 achieved significant outcomes that enhanced their operational efficiency and prepared them for ongoing and future growth.
Optimised DC capacity
Expanded the capacity within their existing facilities, effectively accommodating anticipated growth for the next three years.
Smooth technology and operations transition
- Smooth transition to a RF-based system greatly improved inventory accuracy, reduced labour costs, and enhanced overall operational efficiency.
Enhanced data quality
- Enhanced data quality in Ironman’s updated database facilitated better decision-making and provided deeper operational insights
Ironman 4×4, a leading retailer in off-road vehicle accessories, faced significant challenges with limited warehouse storage capacity and the need for technology and operational support. Partnering with Extolla, they achieved a complete redesign of their warehouse layout and operations.
Key outcomes included optimised DC capacity, a seamless technology transition that enhanced inventory accuracy, reduced labour costs, improved data quality, and overall operational efficiency.
The partnership with Extolla has enabled Ironman to enhance its supply chain performance and prepare for sustained growth.
“Working with Extolla was a game-changer for our distribution centre. Their team thoroughly analysed our needs and developed a customised design to maximise our space while planning for future growth. By optimising material flows and implementing advanced racking solutions, they enabled us to accommodate increased inventory without overextending resources.
The transition from our outdated, paper-based processes to a RF-based system was eased thanks to Extolla’s operational and technology support. As a result, we’ve seen significant improvements in inventory accuracy, labour efficiency, and overall operational effectiveness.“
Chris Sharpe, GM Supply Chain & Procurement
