Integrating Methods Engineering and Ergonomics to Optimize Retail Logistics: A Case Study in Productivity Enhancement and Cost Reduction

The operational inefficiencies of retail distribution centers, such as prolonged order preparation times, incomplete shipments, and increased costs, have a profound impact on supply chain performance and customer satisfaction. Previous studies have primarily focused on general logistics challenges, leaving a research gap in addressing these issues through Methods Engineering. This study aimed to optimize productivity and reduce operational costs in order preparation and dispatch processes by implementing a structured model comprising six interconnected phases. Key improvements included process standardization, ergonomic interventions, and data-driven workflow optimization. The results demonstrated a 40.85% increase in productivity, a reduction in headcount by 28%, and a 35.29% decrease in logistics costs, alongside a rise in on-time deliveries from 92% to 96.1%. These findings contribute to the academic field by providing a replicable and scalable framework, fostering both operational efficiency and worker safety. Future research should explore advanced technologies like automation to further enhance the model’s adaptability.