The Toupargel group is leader in the home food delivery market and chose LM7® to equip the 4 Toupargel distribution platforms.
Logistic and IT reorganisation
In 2003, Toupargel, a major name in the frozen products market since 1947, purchased Agrigel and became the leader of the home distribution of frozen products with a 36% market share and coverage all over France.
Two different organisations
However, the two companies had different ideas of order preparation: Toupargel had an individual and semi-automatic order preparation on two platforms in Civrieux and Poitiers covering 75% of the country. Agrigel had manual preparation for the mobile outlets in a central warehouse in Argentan and 9 warehouses all over the country. This merger was intended to allow Agrigel to go from the mobile outlet order preparation to individual order preparation and handle 25 000 orders a day instead of 500, and to move from mobile outlets to telephone sales.
New logistic scheme
So a logistic plan was launched to handle all order preparation for the « frozen » activity via 4 platforms covering the whole country: Argentan, Civrieux, Montauban and Poitiers. Therefore Toupargel also chose a common ERP, i.e. SAP, for purchase and supply, and LM7® by a-SIS for the warehouse management.
Implementation of the new solution on all sites
A gradual implementation
Up to 2005, the change was gradual: the actvities were transferred one by one from the Agrigel warehouses to the new platforms. In January 2006, 80 % of the Agrigel order preparation were carried out by the new platforms. Between May 2005 and February 2006, LM7® was implemented on each platform.
By installing LM7®, Toupargel wanted to process a high number of order lines while preparing and dispatching all orders by telephone sales. LM7®'s aim was to become more reliable for the goods-in and stock management by making feature statements at goods-in.
Stock level reorganisation
To optimize the replenishment movements, Toupargel chose to handle three stock levels from goods-in : reserve, box picking (area not available for picking) and dynamic picking. The replenishment missions are carried out in two steps: a first step consisting of the replenishment of dynamic picking from box picking (the operator handles boxes) as soon as the thresholds have been reached. A second step consists of replenishing box picking from reserve (the operator handles pallets).
To allow the warehouse manager to monitor all site activity and avoid blockages, a specific monitoring screen has been developed for installation. This screen shows in one view the number of rounds in progress, the progress of the grouped picking, Savoye's packing station activity, the number of boxes missing, the weight control station load rate , but also the sorting lanes.
a-SIS also installed LM_WCS to check Savoye's automated lines and the packing stations. So the Toupargel group could take advantage of the synergy created by the two Legris Industries group companies, especially as far as follow up and responsiveness are concerned.
Since the implementation of LM7®, Toupargel observed an increase in the flexibility of its logistic organization reinforced by the real time follow up of the activity for each site. LM7® allowed picking optimization in straight flow, the efficient management of special offers, and the total traceability of the products to ensure the continuity of the cold chain.
Always looking for new ways to optimise activity, Toupargel is currently developing ideas for the voice picking …