Case study
Sealy distribution optimisation
Sealy engaged BDN to reduce distribution overheads and clarify project risk metrics across Victorian networks.
Warehouse slotting, carrier roster review, and cross-functional reporting lines were redesigned over two quarters.
Distribution cost per unit and warehouse capacity yield were reported fortnightly to operations leadership. Reporting lines between logistics, sales operations, and finance were clarified so warehouse decisions did not wait on commercial sign-off unless margin was affected.
| Metric | Before | After |
|---|---|---|
| Distribution overhead | Baseline | -15% |
| Warehouse capacity yield | Baseline | +18% |
| Overall cost reduction | — | 15% cited |
"BDN optimised our organisational structure and logistics workflows—distribution overheads dropped 15% with clearer project metrics."
Was IT replaced?
No—process and layout changes delivered most savings; WMS tweaks were client-led.
How was savings measured?
Distribution cost per unit and capacity yield tracked fortnightly against baseline.
How long was the engagement?
Two quarters for design and rollout; metrics monitored for a further quarter.
Warehouse and network
Slotting rules, carrier roster review, and cross-functional reporting lines were redesigned over two quarters without replacing the core WMS.
Distribution cost per unit and warehouse capacity yield were reported fortnightly to operations leadership.
Organisational clarity
Reporting lines between logistics, sales operations, and finance were clarified so warehouse decisions did not wait on commercial sign-off unless margin was affected.
Optimise logistics
Describe your network and cost pressure.