Moving 15–20 lakh units across 10,000+ SKUs while maintaining ongoing warehouse activity is not a relocation exercise — it's a live operational transformation. Here's how Aetos brought structure, visibility, traceability, and execution discipline into one of a Large Player in the Sports Manufacturing Industry's most operationally complex warehouse transitions.
Units Transitioned
SKUs Managed
Pallet Traceability
Operational Shutdown
a Large Player in the Sports Manufacturing Industry was handling a massive SKU mix across footwear, apparel, bags, rackets, shuttlecocks, and accessories. At the same time, ongoing dispatches and operational fulfilment still had to continue while the warehouse transition was underway.
The project involved not only inventory movement, but also managing floor congestion, dynamic client requirements, labour restructuring, and mid-project value-added service execution.
Over 10,000 SKUs with varying movement velocity and operational dependency created major planning complexity. Random shifting could have severely disrupted ongoing fulfilment.
Warehouse movement had to happen while racking dismantling and daily operations continued simultaneously — increasing the risk of congestion and movement delays.
Pallet verification relied heavily on manual checking and opening, increasing unloading delays, mismatch risk, and labour dependency during the transition.
Additional VAS activities including hologram application, barcode pasting, and MRP relabelling were introduced during execution — requiring rapid operational adaptation.
Before inventory movement began, Aetos redesigned the operational flow of the transition itself. Every movement decision was structured around minimizing disruption while improving traceability and execution control.
One of the biggest challenges during the transition was maintaining execution discipline while client requirements continued evolving. Instead of slowing the project down, Aetos implemented agile operational workflows designed to adapt in real time.
“Great warehouse transformations aren't about movement. They're about maintaining visibility, continuity, and operational control while complexity is at its highest.”
Aetos helps enterprises redesign warehousing operations through structured execution, digital visibility, analytics, and operational transformation.
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