Executive Summary
Regional distribution review — executive summary
Operations review for a mid-market food manufacturer, six-week engagement.
The current three-depot network was designed for a product mix the business no longer sells. Volume has shifted 41% toward chilled lines since 2023, but the network still optimises for ambient pallet throughput. The result is a cost base that rises faster than revenue and a service level that is respectable on average and poor where it matters.
What we found
- Chilled orders travel 2.3 times further per case than ambient, because only the northern depot is temperature-capable at scale.
- On-time-in-full is 96.4% overall but 88.1% for the top twenty chilled accounts, which represent 34% of margin.
- Third-party haulage now absorbs 18% of distribution spend, up from 7% two years ago, and is used reactively rather than by plan.
- Depot labour is not the problem: productivity is within 4% of sector benchmark at all three sites.
What we recommend
Convert the central depot to mixed-temperature operation rather than building a fourth site. The capital requirement is £2.1m against £6.4m for a new build, and the modelled service improvement is materially the same for the accounts that matter. Retire the reactive haulage arrangement in favour of two contracted lanes.
What it is worth
On the modelled case, £1.4m of annual distribution cost and a move to 95%+ OTIF on the top-twenty accounts within nine months. Payback falls in month eighteen. The principal risk is conversion downtime at the central site; section 6 sets out a phased approach that keeps 70% of capacity live throughout.
Generated from the engagement's findings and the firm's operations methodology, then edited by the engagement lead.