Warehouse inefficiencies rarely announce themselves. They show up as slow picks, inaccurate counts, congestion on the floor, excess inventory, and missed shipments.
RTG Solutions Group provides warehouse optimization consulting for mid-sized manufacturers and distributors. We improve flow, tighten controls, and build repeatable performance through disciplined processes, Lean execution, and better system alignment.
Inventory Accuracy
Cycle count discipline, location control, and WMS alignment.
Throughput & Pick Speed
Optimized slotting, reduced congestion, cleaner handoffs.
Space & Labor Utilization
Layout design, staging logic, labor balancing.
Warehouse improvement fails when it stops at analysis. Our 4-Phase Approach™ moves from floor-level diagnosis to measurable performance gains—then operationalizes them.
Baseline & bottlenecks
Warehouse walk, data pull, KPI baseline.
Map receiving, put-away, picking, slotting, and cycle counts.
Identify accuracy gaps, labor drag, and WMS misalignment.
Design & Optimize
Re-slot inventory by velocity and margin.
Redesign flow, rebalance labor, tune WMS settings.
Lead Kaizen events and implement new control rhythms.
Prove Repeatability
Parallel test new processes.
Validate accuracy, throughput, and labor KPIs.
Fine-tune reorder logic and supervisor cadence.
Lock in Discipline
Formalize SOPs and governance.
Train warehouse leads and supervisors.
Establish KPI review rhythm and accountability structure.
Warehouse optimization starts on the floor. We analyze layout, slotting, travel paths, labor utilization, and system signals to remove friction, stabilize material flow, and restore operational control.
We recalibrate WMS logic, replenishment triggers, location controls, and material release signals directly inside your ERP or WMS. No bolt-on tools. No spreadsheet workarounds.
We document standard work, picking protocols, cycle count discipline, line-feeding routines, and escalation paths. Supervisors and operators are trained side by side so processes become repeatable and performance is owned internally.
When layout, labor planning, slotting strategy, and system signals are aligned, picks accelerate, production is fed reliably, errors decline, and working capital tightens.
Many warehouse optimization projects deliver measurable financial impact within six to nine months, depending on scale and system complexity.
Warehouse Optimization Case Study | ArcelorMittal
At a Texas steel facility, inventory accuracy had dropped to 82%, creating production risk, excess safety stock, and unreliable SAP data. Warehouse transactions and material flow were inconsistent.
RTG led a focused Kaizen event to baseline receiving, storage, staging, and line feed. We corrected system-to-floor gaps, strengthened cycle count governance, and recalibrated SAP min/max logic with live KPI tracking.
98.2% inventory accuracy and $1M reduction in excess inventory within six months.
98.2%
Inventory accuracy (up from 87%)
$1.08M
Cost savings from write-off reduction
35%
Increase in operational efficiency
20%
Reduction in inventory lead time
Warehouse optimization requires disciplined processes, clear ownership, and properly configured ERP/WMS systems.
We align material flow, inventory controls, and KPIs to drive measurable gains in throughput, accuracy, and labor productivity.
Sustainable warehouse performance starts on the floor. We engage supervisors, leads, and operators early to align receiving, putaway, picking, and staging to clear standards and KPIs.
Standard work, slotting logic, cycle count governance, and clear escalation paths reduce travel time, picking errors, and material flow bottlenecks. Execution becomes predictable.
ERP and WMS settings only work when they mirror actual warehouse behavior. We align transactions, bin logic, and replenishment rules to real material movement—so data drives action, not confusion.
A warehouse optimization consultant improves layout, material flow, labor productivity, and ERP/WMS configuration to increase throughput and accuracy. RTG implements changes on the floor — not just recommendations.
Most warehouse optimization projects take 8–16 weeks, depending on facility size and system complexity. Measurable performance gains often begin within the first 30–60 days.
Yes. Most performance issues stem from configuration gaps and process breakdowns, not the software itself. We recalibrate controls and workflows inside your existing ERP or WMS — and when a system change is warranted, our WMS consulting covers selection, implementation, and full warehouse adoption.
Key warehouse KPIs include inventory accuracy, order fill rate, dock-to-stock time, pick productivity, labor utilization, and carrying cost. These metrics link warehouse performance directly to financial impact.
Yes. We support manufacturing plants and distribution centers by aligning warehouse operations with production planning, procurement, and customer fulfillment. If inventory accuracy and control are a core concern, our inventory management for manufacturers services address the processes, parameters, and system settings that keep stock reliable across both environments.
Kaizen events bring cross-functional teams together to eliminate waste, streamline material flow, and redesign workflows quickly. Structured events accelerate measurable gains.
Improved inventory accuracy and tighter controls reduce excess stock and write-offs. This frees trapped working capital and improves financial visibility.
The warehouse sits at the execution end of your supply chain. When slotting, pick paths, and receiving workflows are dialed in, the rest of the chain — planning, procurement, fulfillment — runs more predictably. Our supply chain consulting addresses the broader system when issues extend beyond the four walls.
Often the process and configuration work comes first. We fix what’s broken in the current setup before recommending new technology. When a system change is the right call, our team supports ERP and WMS implementation so the transition builds on a clean operational foundation.
We’re operators first, consultants second. We work with your team on the floor, not from a slide deck.
Our RTG 4-Phase Approach™ moves quickly from diagnosis to execution. We don’t hand over recommendations and disappear. We lead implementation, validate results, and build internal ownership. KPIs move within weeks, not quarters.
Khris K. Bhattan, MBA
President, RTG Solutions Group. Khris brings 25+ years of hands-on leadership in manufacturing, inventory control, and supply chain operations. He has led more than 100 optimization and ERP implementation projects across industrial, retail, and government sectors. His work focuses on measurable financial impact, operational discipline, and sustainable change.
