Growing Fast—But Only if the Value Chain Keeps Up: Connecting Production, Inventory, and Deliveries in Real Time

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Une ligne d’emballage montrant des caisses de boissons emballées et préparées pour la distribution

The Overview

The Challenges

The Solution

The Benefits

Results and Forecasts

Growth That Disrupts Operational Balance

Based in the heart of Quebec, our client is a key player in the production and distribution of hygienic beverages. With a network spanning from Trois-Rivières to Rimouski, through Québec City and Saguenay, the company combines strong local expertise with a finely tuned logistics network to meet rising demand.

But rapid growth comes with challenges. Unexpected spikes in sales of certain products strained storage capacity. Inventory ballooned, prep space became insufficient, and operations slowed dramatically—especially during seasonal peaks.

A solution was urgently needed. The goal: optimize space, redesign flows, and build a foundation for sustainable growth—without sacrificing efficiency.

Des colis de boissons triés et préparés pour la distribution dans une usine d’emballage

The Challenges

The company faced a pressing issue: rapid, unforeseen sales growth that destabilized its logistics operations.

Inventory Overload: Warehouse capacity was maxed out, complicating order preparation and slashing efficiency.
Prep Area Bottlenecks: Limited space forced teams to work around poorly positioned equipment, increasing unnecessary movement and slowing workflows.
Seasonal Pressure: During peak periods, the problem escalated, causing delays and frustrations for both employees and customers. In short, operations had hit their limits.

To regain balance between efficiency and capacity—and prepare for sustainable growth—the company had to act fast.

The Solution

Redesigning Space and Processes to Support Growth

To meet these challenges, the company adopted a comprehensive, phased approach that combined technology, strategic redesign, and change management. Key initiatives included:

Un employé dans un centre de distribution étiquetant manuellement des colis alignés sur des rangées

Inventory Optimization

A deep dive into inventory management parameters highlighted both best practices already in place and inconsistencies to address. Opportunities for improvement were identified, and fast-moving products were prioritized to ensure optimal turnover. The goal was clear: have the right products at the right time while minimizing the space required.

Warehouse Redesign

Using 3D simulations, the company reimagined its picking and storage areas. Equipment and products were repositioned to create a linear flow, drastically reducing unnecessary movement. This new layout was designed not only to maximize efficiency but also to anticipate an average growth of 37% by 2026.

Cutting-Edge Technologies

The simulations also integrated advanced storage systems, such as FEFO (First Expired, First Out) racking and goods-to-person solutions, to illustrate the future potential of operations. Exposure to these innovations gave the client’s team a fresh vision of what their operations could look like moving forward.

Progressive Improvement Plan

By modeling different future scenarios, the company developed a phased plan to ensure a smooth transition. This roadmap balanced employee experience with strategic investment milestones, enabling adoption of new technologies at the right time while minimizing human impact.

With this strategy, the company didn’t just adapt—it built a strong foundation for efficient, sustainable growth.

The Benefits: A Vision for the Future

The implementation of these solutions is already showing strong potential. With a phased approach and the right technologies, the company is positioned to unlock both operational and strategic gains. Key projections include:

Deux employés dans un entrepôt consultent un logiciel pour localiser efficacement les colis

Phase 1: Warehouse Optimization

Estimated Gains: CAD 0.9 million
ROI: 3 months
Key Actions: Reposition pallet racking and mixed-pallet equipment, add a new dock, acquire dynamic storage systems and a new packing machine

Phase 2: Systems Modernization

Integration of a new ERP and WMS to optimize operations
Implementation of KPIs and sensors to track docking times and improve real-time performance visibility

Overall Improvements

Increased Capacity: 35% more prep area to support projected growth by 2026
Boosted Efficiency: 3,205 km of unnecessary movement eliminated while maintaining order velocity
Employee Satisfaction: Streamlined flows reduced overlap between pallet jacks and forklifts, improving both safety and workplace experience

These aren’t just numbers—they represent a sustainable transformation aligned with the company’s long-term strategy.

A Lasting Transformation to Support Growth

By facing the challenge of rapid, unforeseen growth, this Quebec company proved that constraints can be turned into opportunities. With a structured, phased approach, they not only optimized operations but also laid the groundwork for sustainable, controlled expansion.

The investment projections speak for themselves: significant financial gains, stronger operational efficiency, and more satisfied teams thanks to redesigned processes. These improvements give the company a clear vision of the future—and the right tools to keep pace with growing demand.