Capacity Planning: a Warehouse Dimensioning Project at EssilorLuxottica

This thesis addresses the design and implementation of a new warehouse for finished lenses at the EssilorLuxottica facility. The primary objectives were to expand storage capacity, optimize operational efficiency, and ensure high levels of order fulfillment. The study highlights the importance of effective warehouse dimensioning in Supply Chain Management (SCM) to improve overall business performance and customer satisfaction. The field of application is the ophthalmic lens industry, which presents unique challenges due to the high degree of product customization, extensive inventory requirements, and stringent quality standards. Key factors influencing warehouse design include inventory characteristics, order fulfillment processes, and various physical, economic, and regulatory constraints. Several difficulties were encountered during the project, including tight timelines, budget constraints, and the need to integrate new systems with existing infrastructure. The research demonstrated significant efficiency gains through optimized picking and storage processes, using advanced warehouse management systems and innovative layout designs. Solutions included employing data-driven methods for inventory management, adopting ABC classification for better space utilization, and implementing user-friendly interfaces for warehouse staff. The project achieved notable improvements in operational efficiency, space utilization, and order fulfillment rates, largely due to the collaborative efforts of multiple teams. The thesis concludes with recommendations for future improvements, emphasizing continuous optimization and the ability to adapt to future challenges in supply chain operations.