All hands on deck for the implementation of a new warehouse layout
At Kovax, a leading supplier of sanding and polishing solutions, significant revenue growth sparked the need to optimise its warehouse operations. For an efficient warehouse redesign, the company sought advice from Data Science consultancy CQM. In just five weeks of research and three days of company-wide reorganisation, Kovax implemented a new warehouse layout and introduced data-driven processes. Curious about how this transformation took shape? Read on!
Warehouse Optimisation as a Foundation for Future Growth
From its base in Almelo, Kovax supplies products across Europe and parts of Africa. The range includes everything from fine sanding paper for luxury cars like Lamborghini and Porsche to polishing products for yachts. Despite being in operation since 1930, the past few years have seen enormous growth—from €2.5 million to €20 million in annual revenue. The warehouse grew along with this success, expanding from 3,000 to 5,700 m². Nine years ago, Kovax anticipated future growth by purchasing additional warehouse space, gradually converting temporarily rented areas into operational storage.
While the warehouse team managed the expansion admirably, inefficiencies began to surface over time.
Willem Mulderij, CEO of Kovax, convinced his team of the need to critically assess the warehouse to prepare for future growth. Were the fast-moving products still in the right places? How efficient were the buffer zones? And were the pickers’ routes optimally designed? To find a data-driven solution for a new warehouse layout, Kovax turned to a Data Science consultancy experienced in resolving logistical challenges in distribution centres.
An SME with Big Vision for Warehouse Innovation
"Many people think such a specialised Data Science approach is only suited to large multinational distribution centres, not for optimising a relatively small warehouse," says Willem Mulderij. "But we occupy a unique market position, are willing to think differently, and believe in the power of innovation. Rather than pursuing market dominance, we focus on building sustainable relationships with our partners, customers, and employees."
This vision reflects a deep respect for customer commitments and genuine care for employees. "Failing to deliver an order on time can have major consequences for our clients. It's not just about numbers on paper; it impacts the people working here too." For Willem, the well-being of employees is paramount when considering the company’s future. "A business relies on the people who work there—they’re essential. That’s why it was so important to involve them in this project from the start."
Teamwork Makes Lean Work
While one might expect a Japanese-owned company like Kovax to be heavily influenced by Eastern philosophies and methods like Six Sigma for efficiency, Willem draws his greatest inspiration from his past as a basketball coach. He has learned that even the best individual players can only succeed when they work as a team. “When do you play better? When everyone tries to score at the same time, or when the team ensures the best player gets the ball at the right moment?” This experience has ingrained "lean working"—eliminating waste and optimising processes—into Kovax’s culture.
To foster teamwork, Kovax organises weekly sports sessions for its employees and carefully selects partners who not only have expertise but also share their values of teamwork and customer focus. This made CQM, with its emphasis on warehouse design, logistics processes, and the human element, a natural fit.
CQM Delivered More Than Smart Warehousing Expertise
"It was clear we needed a partner with expertise in Operations Research—optimising complex systems—Smart Logistics, and Data-Driven Warehousing," Willem explains. Kovax quickly chose CQM because of its shared emphasis on personal contact, loyalty, and straightforward communication.
“CQM helped us implement the latest technologies in a way that aligned with our employees’ needs. Through this connection and their personal approach throughout the project, we were able to quickly and effectively deliver concrete results.”
Data-Driven Approach + Human Focus = Future-Proofing
The partnership with CQM was a resounding success. Minou Voortman, project lead at CQM, reflects on the collaboration: "Our data analysis confirmed that the existing warehouse layout was no longer optimal. After a thorough dive into the data and patterns, we presented a detailed plan for a new warehouse layout. By centralising fast movers and optimising picking routes, we significantly reduced order picking times.
For example, in Hall A, the chance of a short picking route increased from 10% to 46% with the new design. We also ensured the layout was flexible and future-proof. By working closely with Kovax’s team, we created a solution that not only boosted efficiency but also met employees' needs and enhanced customer satisfaction."
Implementation of the New Warehouse Layout
The new layout wasn’t just planned—it had to be executed. At the end of September, all Kovax employees came together to reorganise the warehouse in just three days. The entire company pitched in, clearing spaces, relocating packing stations, and refilling shelves. This extraordinary team effort, combined with data-driven insights, created a future-ready workspace that saves time and costs while improving employee satisfaction.
Satisfied employees and a top-notch warehouse lead to faster deliveries and happier customers—a true win-win situation.
This project demonstrates that Data Science is not just about numbers; it’s also about people. By putting the human factor at the centre, data’s full potential can be realised. It also highlights how Data Science can drive significant improvements, even in smaller organisations.
Want to Improve Your Warehouse Efficiency and Customer Satisfaction?
Explore how data-driven insights can benefit your organisation! Contact Minou Voortman to discover if a warehouse scan is right for you.
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