Project Pavilion successfully delivered for The Wonder Group by Logistics Improvement Group Ltd.

Project Pavilion successfully delivered for The Wonder Group by Logistics Improvement Group Ltd.

Well, here we are having successfully planned, delivered, and closed project Pavilion for our client The Wonder Group on plan at the end of June 2023

The Wonder Group Management Buy Out, the catalyst for change.

Following their MBO in January 2021, one of the first strategic moves was to rationalise the group’s UK distribution network of 4 sites. The key enabler to this was to introduce automation to its largest site in Milton Keynes.

The business, (which includes brands such as Amscan, Ginger Ray, PDMP and Party Delights) conducted their own design and procurement process and decided on an AutoStore solution. Board advice was to engage a professional external PMO, and the business then approached LiG to partner in the planning and executing project Pavilion.

Starting on the 6th September 2021 Ellis Williams, Director at LiG was engaged and the 22-month journey began until its conclusion on plan in June 2023.

Planning and Governance set up.

The initial phase from September to November 2021 was to plan the whole project and agree that the business’s aspirational milestones were feasible. Working with Rob Branigan, VP Global Logistics and Jane Astley, Group Procurement Manager, several iterations of an overarching plan were detailed until a final version that met the business case deadline was agreed.

Once that was done, the governance process was agreed and then implemented with 19 workstreams established and workstream leads appointed. This process was followed though until the final Go Live in June 2023.

Deliverables

Using the LiG governance model the following deliverables were implemented,

Move from voice picking to RF picking.

The first major change to the warehouse operation was delivered in August 2022

Warehouse preparation

Dismantling racking and repositioning pick faces, so that when the rack and mezzanine builders arrived on site on January 4th, 2022, they had a clear working area.

Constantly updating the WMS

As work developed and pick paths were periodically moved, the WMS required updating to ensure that products could be found and picked.

Laser floor survey and levelling

With the requirement for a ‘superflat’ floor upon which to locate the AutoStore. The required FF tolerances were met.

Dismantling of old racking and mezzanine floor

Creating room for new racking

Build of new racking and a new and larger mezzanine floor

This provided more capacity for stock and VAS. The level of cooperation between the Amscan workstream leads and the contractor was key to success here with all parties working constructively to achieve the goal and delivery of August 2022.

Installation, testing and commissioning of an AutoStore and related conveyoring.

The AutoStore was the heart of the project from a warehousing perspective. With a capacity of 39,100 bins and 64 robots to service the picking of product for The Wonder Group brands such as Amscan, Ginger Ray, PDMP and Party Delights.

Business process re-engineering

Classic “as is, gap analysis and to be” documented in a Functional Design Specification document representing the changes to various processes across the supply chain and logistics operations.

Integration of 10 IT systems

Various brands’ legacy systems required integrating with the main ERP system S2K and that integrating with Element Logic’s eManager that controls the AutoStore. Another integration with the Sorted Transport Management System was key.

Rigorous Testing

Testing was rigorously applied to all aspects of the various IT developments and strict assessments applied before all Go Live steps.

Closure of 3 warehouse operations

The closures required migrating stock from 2 Wonder Group warehouses and 1 outsourced site, all of which was completed on time.

Consultation and redundancy process

With the closure of 3 operations managing the separate consultation and redundancy process was delivered with great care and professionalism by the HR team.

Master Data

The creation of standardisation of the business’s master data was an ongoing process throughout the programme.

Phased Go Live

The first Go Live step on 3rd January 2023 was the implementation of the AutoStore picking which coincided with the launch of the Spring Summer range for the Ginger Ray brand.

The second step was the launch of the Party Delights Market Place brand on 26th April.

The final and biggest migration and launch was Party Delights in June.

All the launches were successfully implemented, with the usual minor issues. LiG’s issue management process was used to classify and resolve these quickly and effectively.

 

Credit where credit is due.

Pavilion is a classic case of large complex programme planned and delivered under a proven LiG governance model.

LiG would like to express our thanks to the entire Wonder Group team who have been involved, from the fantastic project team, the warehouse colleagues at all sites, the various suppliers and also to the board and senior stakeholders who were supportive during a time of immense change.
Both as a business and as one of its Directors LiG is proud to have played its part in this exciting project which will benefit The Wonder Group for years to come.

Talk to LiG

If you need support on a major business transformation project, similar to Pavilion, please contact us on 020 4587 5487
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