Success Stories

Patrick Daly delivers real results, helping businesses worldwide optimise supply chains, cut costs, and boost growth through practical, proven solutions.

Success Stories

Real Results from Logistics & Supply Chain Advisory and Business Optimization

Patrick Daly has worked with organizations across the globe to transform their supply chain operations—enhancing performance, reducing cost, and supporting strategic growth. Here’s a sample of what that looks like in practice:

Global Manufacturing Client in Medical Devices Sector – Warehouse Optimization

Client Overview:
A multinational manufacturing company with EMEA headquarters in Ireland and with production and distribution facilities across Europe. The business was facing operational challenges at one of its distribution facilities located in Germany and we helped them to identify opportunities to improve warehouse layout design, material flow, work processes, and organizational structure.

Challenge:

  • Outdated warehouse layout
  • Inefficient material flows
  • Inconsistent warehouse procedures
  • Unstructured working day
  • Unclear lines of communication

Patrick’s Approach:
Patrick worked in an active partner role to support structural and process-related improvements through detailed data analysis, CAD layout design, process mapping, and workspace redesign. Patrick also conducted root cause analysis, specified equipment needs, and supported implementation planning. In parallel, he acted in an advisory capacity to the management team to guide organisational improvements and develop a KPI framework aligned with best practices. Throughout, he supported the team via unlimited access as required and participated in all key workshops and meetings to ensure knowledge transfer and alignment.

Solutions Implemented:

  • Redesigned warehouse layout to improve material flow and optimise storage efficiency
  • Introduced slotting strategies and warehouse performance metrics
  • Introduced standardised work processes including pick face replenishment to right-sized, fixed pick faces
  • Introduced structured working day and advance planning to match resource deployment to workload

Results Delivered:

  • 25% reduction improvement in productivity within 12 months
  • 40% improvement in storage capacity
  • 15% reduction in inventory holding costs
  • On-time delivery increased from 83% to 96%

Client Feedback:
“Patrick brought clarity, structure, and real-world insight to a complex intralogistics challenge. His strategic input and practical solutions made an immediate impact on the efficiency and effectiveness of our warehouse operations.”
— Head of International Logistics, Global Manufacturing Group

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Irish Clothing and Footwear Distributor – Distribution Centre Automation

Client Overview:
A mid-sized, family-owned distributor specializing in clothing and footwear for retail stores and direct-to-consumer e-commerce was experiencing significant growth—particularly through its online channel. This surge in demand led to increased throughput and placed pressure on labour resources in an already constrained job market. To meet this growing demand and streamline operations, the company sought to implement an automated solution for storage and order picking. Their goals included boosting throughput, enhancing efficiency and accuracy, and gaining better operational control.

Challenge:

  • Limited in-house knowledge of the latest applicable automated solutions available on the market.
  • Requirement to provide a well-put-together specification of requirements including analysis of stock profiles and order patterns
  • Need to develop objective criteria and structured approach to evaluating and selecting preferred solution and partner.
  • Requirement to validate performance metrics post installation and commissioning.

Patrick’s Approach:
Patrick was engaged to develop the specification for the automated solution, engage qualified solutions providers and integrators, evaluate their concepts and proposals and assist the client management team in selecting the best solution to meet their requirements and to guide and to act as trusted advisor to the client management team throughout the implementation phases of installation, commissioning, testing, and go-live.

Solutions Implemented:

  • Client data sets and order profiles specified and analysed.
  • Solutions capacity, throughput and performance specifications defined and communicated to solutions providers and integrators.
  • Solutions proposals from integrators for solutions such as Miniloads, Shuttles and AutoStore evaluated.
  • Evaluation criteria set and scoring methodology developed and applied
  • Selection of preferred partner and solution.
  • Acceptance testing to ensure performance thresholds met.

Results Delivered:

  • Space optimization with approximately 75% reduction in floor space required to store the inventory 🏢
  • Increased efficiency with 300% Throughput increase ⚡
  • Improved accuracy with error rates dropping by 90% 🎯
  • Solution Scalable without downtime 📈
  • Lower Operational Costs with Labour Cost Savings of 50% 💰
  • Enhanced Inventory Management with accuracy improved by 30% 📦
  • Better Ergonomics and Safety 🦺

Client Feedback:
“Patrick’s guidance gave us the clarity and confidence to specify and select the right automation solution for our business from the many options available on the market. His understanding of business strategy and execution was exactly what we needed.”
— Managing Director, Irish Clothing and Footwear Distributor

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Global Manufacturing Client in Beverage Sector – Warehouse Optimization

Client Overview

A leading multinational manufacturer in the beverage industry with EMEA headquarters in Ireland and global production and distribution facilities. Due to continuous growth in export volumes from its Ireland-based plants, the company faced serious capacity constraints at its adjacent Finished Goods Warehouse. This facility was the primary despatch point to EMEA sister companies.

Rather than committing to a costly multimillion-euro warehouse expansion, the company engaged Patrick to explore viable alternatives that would support increasing throughput demands over the next five years—without immediate infrastructural investment.

Challenge

  • Storage capacity at the Finished Goods Warehouse frequently maxed out during peak periods
  • Site constraints limited the feasibility of on-site expansion
  • A fixed number of loading docks and despatch lanes created a bottleneck in operations
  • A complex SKU profile and stringent fulfilment requirements added operational complexity

Patrick’s Approach

Patrick collaborated closely with the client using a dual-track strategy:

  1. Short-Term Relief Plan (18-month horizon):
    Targeted actions to quickly alleviate warehouse pressure and support immediate throughput growth.
  2. Long-Term Strategic Planning (longer-term horizon):
    Developed future-ready solutions to sustainably manage projected capacity demands.

Extensive data analysis was conducted across a full seasonal cycle, covering:

  • Inbound receipts
  • Storage and put-away patterns
  • Picking and despatch operations

This analysis allowed Patrick to model the impact of proposed changes under various growth scenarios, evaluating their effects on:

  • Storage capacity
  • Warehouse occupancy
  • Staging and loading efficiency

Potential warehouse redesigns were also explored—both conventional and automated storage/retrieval systems—assessing:

  • Capacity gains
  • Required capital expenditure (CapEx)
  • Return on investment (ROI)

Solutions Implemented

  • 📍 Strategic Offsite Storage: Identified SKU groups suitable for offsite storage and despatch to ease on-site congestion
  • 📦 Viable future options for automation to dramatically increase both future capacity and productivity identified and quantified.
  • 🕒 Timing issue on picking to staging and loading identified with high-potential to increase loading throughput without infrastructural investments

Results Delivered

  • 25–30% increase in throughput within the existing despatch and loading infrastructure—achieved through minimal operational changes
  • 15–20% short-term storage capacity release via temporary offsite storage and despatch solutions
  • Up to 100% storage capacity increase achievable with a long-term automated solution
  • 2–3 year postponement in the need for major CapEx investment due to effectiveness of interim measures

💬 Client Feedback

Patrick brought a strategic understanding of our business together with tactical operational insight and analytical capability to help us gain clarity and develop a strategic roadmap for the future—while delivering immediate, impactful improvements to address our current challenges.”

— Supply Chain Director, Global Manufacturing Group

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What Our Clients Say

Hear from businesses that have transformed their supply chains with Patrick Daly’s expert guidance. Real results, real impact.