Supply Chain Performance

Project 45: A revolution in load handling

The average load turnaround time on logistics platforms is 2.5 hours. FM Logistic platform in Mszczonów has decided to change this standard.

On December 2, 2024

The average load turnaround time on logistics platforms is 2.5 hours, which is widely accepted as a standard within the industry. However, one of FM Logistic’s Polish branches chose to deviate from this pattern by developing and implementing an innovative project, codenamed “Projekt 45.” The new process reduces the time required for handling one driver by 150%.

The objective of “Projekt 45” was to optimise the distribution processes for handling drivers on the logistics platform, with the goal of increasing the capacity of the warehouses. From the outset, the
objective was to achieve a new loading standard of 45 minutes door-to-door, defined as the time elapsed from passing the platform gates to leaving the platform. The challenge was significant, given that the typical handling time in this type of warehousing facility is 2.5 hours. The optimisation of the work covered all key logistical areas, from reception to loading to transport. In developing measures, the objective was to focus on both infrastructure and end-to-end system solutions. State-of-the-art technologies, such as autodocks, have been introduced and all IT operations have been combined with technical efforts, with satisfactory results.

The process of developing and implementing solutions was highly challenging, as it spanned numerous areas and necessitated the simultaneous implementation of multiple changes. The success of this project would not have been possible without the input of every team member, from the warehouse staff to the administrative, security and IT departments. Thanks to the seamless operation, we can consider the project complete. However, we are still developing and improving it, and we have already recorded instances of services being completed in under 45 minutes. It is our intention to implement this standard across all our units as soon as possible, states Mariusz Jóźwik, Regional Director – Warehousing, Co-packing, Co-manufacturing at FM Logistic Central Europe.

The “Projekt 45” pilot scheme is currently underway at a warehouse in Mszczonów, near Warsaw. The facility covers an area of approximately 83,000 sq m and employs 350 people. The facility
handles approximately 120,000 pallets per month, with up to 8,000 pallets per day during peak periods. The large scale of the operation, coupled with the numerous procedures, including loading
and completing the requisite documents, resulted in a significant increase in driver handling time. However, thanks to the procedures implemented as part of the project, all these processes have been significantly streamlined.

Enhanced employee comfort, cost savings and reduced environmental impact

The implementation of the project has yielded significant benefits across a range of areas. Most importantly, the optimisation of operations has enabled significant time savings in the loading
process, which has in turn allowed for sustained high throughput in the warehouse. These improvements have also helped to reduce costs, benefiting both the unit and customers. By reducing expenditure, the warehouse was able to enhance the competitiveness of its offering, which in turn increased customer satisfaction by lowering the price of individual services. The streamlining of all processes has also improved the quality of service during sales peaks, and faster deliveries have enabled producers to manage their stock effectively at these challenging times.

The implementation of “Projekt 45” has enhanced the level of comfort experienced by both warehouse staff and drivers, who are now able to manage their time more effectively. The new system allows drivers to spend significantly less time in the warehouse, enabling them to get on the road more quickly. Furthermore, it permits warehouse staff to increase the number of vehicles they handle, thereby enhancing overall efficiency.

Furthermore, this optimisation contributes to environmental sustainability: Thanks to a number of improvements, CO 2 emissions have been reduced. Reducing the time taken to load trucks can lead to emissions savings of up to 933 kg per month. Similarly, reducing genset operation during loading can result in a reduction of 1,835 kg per year.

Undoubtedly, “Projekt 45” represents a revolutionary development in the Polish logistics market. Going below the average loading time by more than 100 minutes is a very big step in improving
driver handling and the operation of the logistics platform. The solution is currently operational in the Mszczonów warehouse, with plans to adapt the project for implementation in other FM Logistic
units in Poland.