Lean Warehouse Management Consulting From TXM Lean Solutions

Choosing a consulting partner is about more than just finding someone who understands Lean theory it’s about finding a team that understands the complexity of the warehouse floor.

We stand out because we focus on practical, sustainable results rather than complex academic models. We recognise that every late delivery or picking error has a direct impact on your reputation and your bottom line.

Our global experience across diverse industries allows us to cross-pollinate best practices, bringing innovative solutions to your specific challenges.

When you choose TXM, you aren’t just getting a consultant you are getting a partner dedicated to transforming your warehouse from a cost centre into a finely tuned profit maker.

We bring a unique blend of global expertise and local smarts to every project. Our consultants aren’t just career coaches; they are former business leaders who have managed warehouses and supply chains firsthand. This experience of over 200 warehouse projects allows us to bypass theoretical fluff and move straight to solving your core problems. Whether it’s a poor layout, low pick rates, frequent errors, or disengaged staff.

Implementation Over Presentation

At TXM, we believe that adults learn through action, which is why we coach your team through the implementation process in real-time. By piloting changes on the shopfloor, we ensure that every new workflow is robust enough to handle the pressures of your daily peak periods.

Tailored Frameworks, Not Cookie-Cutter Templates

We recognise that a medium-sized distributor has different constraints than a global 3PL. Our Facility Layout Development Process (FLDP)® is a proprietary methodology that builds a layout around your unique value stream. FLDP enables you to build an operational system that is perfectly aligned with your specific customer demands and business strategy.

Sustaining the Culture

The TXM advantage lies in our focus on leadership. Through our Lean Daily Leadership Process® (LDLP), we empower your supervisors to lead the change.

By establishing daily routines and visual performance metrics, we ensure that the improvements we make today don’t return to the old ways of working once we leave.

We don’t just fix your warehouse we build your team’s capability to keep continually improving it.

STS Ltd: Increasing Output by 25% Without Extra Staff

STS Ltd, a construction materials supplier, faced significant congestion and safety risks after moving into a new site with a temporary layout. The lack of flow was hindering their ability to meet rising demand.

The Challenge: Stock was unsafely stored, height was wasted, and pickers were dealing with excessive motion and “double handling” of goods.

The TXM Solution: Using our Facility Layout Development Process (FLDP)®, we mapped the top 10 pick items and redesigned the warehouse flow. We categorised inventory using ABCD analysis to ensure high-velocity items were positioned for the fastest possible access.

The Results: 

• 25% increase in warehouse output with the same number of staff.
• £25,000 annual saving on damaged products due to safer handling.
• Significant improvement in stock accuracy through a new rolling stock-take system.

ICO Bath: Record Growth Through Lead Time Reduction

ICO Bath needed to scale their North American operations to match record-breaking sales. Their crowded warehouse and inconsistent lead times were threatening their reputation for luxury service.

The Challenge: High inventory levels were clogging the warehouse, yet didn’t always align with actual customer demand, resulting in lead times that fluctuated between 7 and 21 days.

The TXM Solution: We implemented an end-to-end supply chain optimization, redesigning the warehouse layout for maximum picking density and establishing a “Made-to-Stock” strategy driven by real-time demand.

The Results:

• 35% reduction in finished goods inventory.
• 58% increase in inventory turns, significantly freeing up cash flow.
• 21% boost in labour productivity.

Stabilised lead times at a consistent 4-day window.

Is your warehouse a strategic asset or a constant bottleneck? In today’s high-velocity market, good enough logistics is a recipe for shrinking margins. If you’re struggling with rising labour costs, inventory inaccuracies, or space constraints, you don’t just need a software update. You need a Lean transformation.

At TXM, we don’t just offer advice we deliver operational excellence. Our Lean Warehouse Management solutions are designed to strip away the hidden waste that drains your profitability.