Client Story


Nuttall helps to ‘deliver’ Christmas for Amazon.

The 2020 global pandemic resulted in a huge boom in online shopping. Amazon reported a blowout third-quarter as sales rocketed and the company tripled its profits with a 37% increase in earnings.

Project Santa.

Increasing staff to meet the forecast of an unprecedented Christmas rush, Amazon were faced with the urgent challenge of making their UK and European warehouses Covid-safe. The project was aptly named ‘Project Santa’.

Amazon’s challenge – to protect key workers during Covid – was exacerbated by the spike in online purchases in the run up to Christmas. Keeping the business running smoothly and safely became mission-critical for the retail giant.

Making it right.

At the beginning of the project, Amazon took a guided tour of our manufacturing facility, which gave them the confidence that we could deliver the highly responsive solution. They came with a set of high-level drawings for warehouse safety screens. However, in practice the design wouldn’t have been quick or easy to install, meaning potential disruption – disruption that Amazon couldn’t allow given the intense demands on the business at that time.

We brought in the fresh eyes and the expertise of our design team to propose a rework. Pragmatic and non-disruptive, Amazon proceeded with our redesigned modular screen system. This included a consolidated number of components for cost efficiency and increased flexibility.

The need for speed.

We went from concept to prototype delivery in just 7 days. We built a full working prototype of over 6000 sqft in our UK facility to ensure the design was robust, resilient and flexible. With the prototype built, the client had the opportunity for all stakeholders to visit, including installation teams to see how the design worked; contributing feedback and refinements to the design ahead of roll out.

Once the design was signed off, we manufactured all metalwork in-house, at speed and at scale. We assembled all components in-house, creating a 25-person assembly-line to roll it out and to pick and pack to meet the deadline. The team had just 4-weeks to produce the screens and meet the logistical challenge of distribution, ahead of the Christmas rush. We planned and managed a phased delivery across all the different warehouses and provided training days so that Amazon’s foremen could see exactly how to fit the screens to ensure performance.

Project Santa. Delivered.The project management was identified as key to the success of the roll out. Our team pinpointed every area where time could be saved, to minimise any operational disruption – down to the smallest detail.

Amazon were delighted with the result. With safe measures in place for staff, Christmas 2020 was a bumper year for Amazon – delivered in-line with their exacting standards for speedy and efficient customer service.

“This was a job that needed responsiveness, speed and scale. It showcases how our team are able to pull out all the stops and adapt to suit the client challenge, with remarkable results,” adds Matt Hornblower, Nuttall CEO.

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