Intralogistics optimization is key to increasing operational efficiency, reducing costs, and improving competitiveness in industrial environments. However, many companies still maintain outdated practices that hinder their growth and cause economic losses that are difficult to detect at first glance.
Could your company be facing these inefficiencies without even knowing it? Below, we reveal 7 common practices that are affecting your facility—and how to fix them.
1. Managing inventory with Excel
Although Excel has been a useful tool for decades, today it is one of the most outdated practices in intralogistics—especially if you’re aiming for real-time traceability and control.
Why is this a problem?
- It doesn’t offer real-time updates.
- It’s prone to human errors.
- It doesn’t allow automated traceability.
- It becomes inefficient as the company grows.
How to optimize it?
- Implement a Warehouse Management System (WMS) for real-time updates.
- Integrate RFID technology or barcodes for precise stock control.
- Digitize your operations with tools designed for industrial logistics.
2. Moving materials with forklifts on inefficient routes
Many companies rely on forklifts or even manual material handling inside the plant. While these solutions may seem cost-effective, they might be slowing down production without you realizing it.
Why is this a problem?
- It increases travel times.
- It creates more traffic and potential accidents on the plant floor.
- It doesn’t make efficient use of available space.
How to optimize it?
- Implement overhead conveyors on second levels to free up floor space.
- Integrate AGVs (autonomous guided vehicles) to optimize material flow.
- Design more efficient logistics circuits with modular tools.
3. Disorganized picking
Picking is one of the most critical tasks in a warehouse. If it’s still done manually and without optimization, mistakes and delays in order preparation are inevitable.
Why is this a problem?
- A lot of time is wasted searching for products.
- There are more mistakes in order preparation.
- It’s difficult to manage demand spikes.
How to optimize it?
- Use Pick to Light to speed up picking and reduce errors.
- Incorporate smart wearables (picking bracelets or gloves) to optimize worker tasks.
- Implement automatic systems to always have the part you need available.
4. Lack of real-time traceability
If you can’t know in real time where your products are within the warehouse or plant, you’re losing control over your production and logistics.
Why is this a problem?
- Products can get lost within the warehouse.
- Production or delivery delays are generated.
- There’s no efficient control during audits or quality issues.
How to optimize it?
- Implement RFID or barcodes for real-time tracking.
- Use traceability software to visualize the material flow.
- Design logistics circuits with fewer error points.
5. Storage without strategy
Storing goods without a rotation logic or without optimizing the available space is a practice to avoid, as it directly impacts logistics costs.
Why is this a problem?
- Products may expire or become obsolete.
- Products get lost in the warehouse.
- Access to materials is inefficient.
How to optimize it?
- Implement a FIFO (First In, First Out) system for perishable goods.
- Apply LIFO (Last In, First Out) for high-turnover products.
- Use dynamic warehouses and vertical storage systems to optimize space.
6. Lack of integration with other areas of the company
Many companies still operate with independent management systems that do not communicate with each other, resulting in inefficiencies and errors in the logistics chain.
Why is this a problem?
- Information is fragmented and doesn’t flow properly.
- Unnecessary manual processes are carried out, increasing the risk of errors.
- It’s hard to react quickly to demand changes or operational issues.
How to optimize it?
- Implement an Integrated Management System (ERP) to centralize information.
- Automate key processes to reduce errors and downtime.
- Adopt technologies like the Internet of Things (IoT) or Artificial Intelligence (AI) for intralogistics optimization.
7. Lack of planning and simulation of logistics flows
Many companies, both small and large, operate without optimized designs for their material flows, leading to inefficiencies, downtime, and resource wastage.
For SMEs, this can result in poorly utilized space and disorganized operations. For large manufacturers, it means production bottlenecks and hidden costs that affect profitability.
Why is this a problem?
- Unnecessary routes are generated, increasing handling time for products.
- Space is wasted, leading to more unnecessary movements.
- Without clear planning, it’s difficult to anticipate operational problems and optimize processes.
How to optimize it?
- Analyze the warehouse layout and reorganize picking and material transport routes.
- Use logistics simulation software to model and optimize workflows before making changes.
- Apply Lean principles to reduce downtime and improve efficiency without major investments.
How to achieve true intralogistics optimization?
Not all companies face the same logistics challenges or require the same solutions. The ideal system depends on multiple factors, such as the type of product, operational volume, available space, and budget.
That’s why, before making drastic changes, it’s essential to identify these outdated practices and implement tailored solutions that drive true intralogistics optimization. Working with experts in logistics flow design and improvement can make the difference between a simple improvement and an efficient, sustainable transformation.
At Esypro, we analyze each case individually to design the most efficient solution based on the specific needs of each client. Our goal is to upgrade your internal logistics without the need for radical changes to your facility.
Contact us and discover how we can help you transform your operation.