As volume and complexity increase
As companies grow, the number of orders, items and exceptions increases. What once worked starts to break down. Lead times increase and productivity comes under pressure. Work needs to be continuously replanned throughout the day.
As complexity increases, it also becomes harder to interpret performance. Problems are visible, but their causes are not always clear.
Improvements in processes, WMS and layout are often implemented ad hoc to resolve issues. As a result, structural improvement remains limited and coherence is lacking. That coherence is key to a controllable and scalable warehouse.