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Al Maya Group automates Central Distribution Center with EPG ONE™ Warehouse Management System (LFS)


EPG in Dubai

Al Maya Group isaDubai based conglomeratewhichhas multiple business verticals:Foodandnon-food productsandover 90 retail stores in theMiddle Eastincludingsupermarkets,internationalbookstores,franchises,andmanyotherlifestyleretail stores.In the foodsector,thecompanyservesthe major supermarket chains in the region. Handling sensitive and temperature-controlled goods is a challenge–especiallybecause Al Mayahas to offer a wide range of productsto all the major retailers in the region through their distribution operations.All of this requires well-functioning logistics.In order to manage theexisting processesand alsobe prepared for the future, thecompanydecided to automate the processes in thecentraldistribution centerforall thesectorswith theEPG ONE™ Warehouse Management System (LFS).Al Mayaalsorequestedthe consulting services of EPGto designthe different storagesolutionsand the overall structure of the warehouse.The goal of having a state-of-the-artdistribution centerwitha WMSwas achieved within a very short time–and without interrupting ongoing operations.

»We are very satisfied with the course of the project, with the support of the EPG team on-site and with the overall planning,« says BharatKorwani, IT Manager of Al Maya Group. »The efficiency and level of detail with which the entire project was carried out really impressed us.«

As one of the largestFMCGdistributorsin the UAE,Al Mayasupplies to all the major retail stores in the region. The focus of the product rangein thedistributiondivisionis on fresh products purchased directly from the countries of origin. Premium customersof their distribution divisioninclude Carrefour,Lulu Hypermarketand other retail stores including their own supermarketchain Al Maya Supermarkets. All the business areas in which Al Maya operates followvery differentand uniquelogistical rules. In addition, the variety of products to be stored isvastand requires the greatest sensitivity in handling, especially in the food segment. Up to 2.500 different articles must be managed.Themain objective is tohandle the goods based onbest-before dates andincompliance with theFiFo(first in, first out) principle.

Al Maya forecasted this requirement much in advance and their prediction was right, due to the increasing order volume, operations can no longer be managed based onold platforms.

Warehouse matrix for optimum warehouse planningand automated processes

EPG's logistics experts developed a warehouse matrix to meet Al Maya's requirements,based onthe key characteristics to be met in termsof the warehousestructure and business requirements. As a result, EPG designed various storage areas and temperature-controlled zones that also considered thespecificrequirements of the individual business units. The introduction of customer classes A, B and C divides thedistributioncenterintoreasonableunits. Before this classification, the handling of thegoods,and the stock overview were mainly dependent on the experience of individual employees.TheFiFohandling and the secure administration of best-before dates werenot possible without errors. Due to the different storage zones–rack storage, pallet floor, filling stations and floor storage–the product groups can now beclearlyassigned.LFS ensures automatic control of the storage areas and offers maximum transparency of the current stock. If required, replenishment is requested automatically.EPG’s warehouse management systemLFSalso controls the sorting of goods according to BBD(best-before-date),to product group and customer.The orders receive anassigned storage location upon receipt.Order processing ishighly reliable inLFS:The warehouse management system controls picking in sequences and, depending on the products ordered, according to priority and shelf life.The goods are assembled on pallets and then loaded onto trucks according to the sequencing so that the goods of the customer who is supplied first are loaded last.More than700orders are processedinAl Maya’s distribution centerdaily.

EPG organized the processes in the new22.000 m² distribution centerand plannedthemoveofgoods to thisnewwarehouse facility–without interrupting day-to-dayoperations.

»LFShas helped us to manage our inventory and overall logistics operationsfor our FMCG distribution divisioninthe most effectiveway,« saysBharatKorwani. »Also, this brought astrict control over theoperation.Italso gave uscomplete visibility to our stockand alsohelped us in BBD maintenance.«

As a result oftheimplementationof LFS, we have an effective supply chain operation now andAl Mayaisable todeliver the goods to our customers on time.BharatKorwanisums up: »We were always able to count on EPG during the entire process changeover and the move–so we are confident that we will rely on the logistics experts for future projects.«Within a short span of time,Al Maya decided tointroduceEPG’s warehouse management systemin twomoredivisions.

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