Client Story #7

Morrisons Capping

Reaching new heights – shelf capping for Morrisons.

Shelf capping is now commonplace amongst the Big 4 retailers when looking to increase efficiency and stock availability in-store. Extra height shelves allow for more product to be stored on the trading floor, out of reach of customers, but handy for replenishment. With the onset of the pandemic, Morrisons urgently needed to free up back-room space for the fulfilment of increased online orders. As a solution, they wanted to increase the height of gondolas throughout their stores. This required a rapid response, smart project management and the ability to deliver with flexibility and at scale.

A rapid-response solution, delivered at scale.

After successfully implementing a solution in two trial stores, Morrisons pushed the button for the order to be delivered in full. It was a mammoth task. We surveyed 200+ stores, produced individual store call offs and began manufacturing everything within a 3-week period. Equipment call offs were challenging, due to the varying formats across the Morrisons estate. We produced post extensions, back panels, shelves and brackets which are standard components, but what was far from standard was the way our operations were able to scale to achieve a rapid roll-out. We had to consider other factors such as bulk heads, special bays and relocating services, lighting and data points, always making sure safety was our main priority.

An epic commitment and jaw-dropping results.

We assembled a dedicated team to oversee the manufacturing of the equipment and a Project Management team to manage the overall deliverables. At the height of the project, we also had more than 100 installers and electricians working through the night at various locations to ensure that implementation was as smooth as possible, with zero disruption to day-time trading.

In total, we manufactured capping shelves for 65,000 bays, involving 320,000 parts and created additional shelf space equivalent to 6.5 football pitches. That’s 48 miles of shelving installed into 209 Morrisons stores in just 11 weeks.

A brilliant outcome for our client and their customers.

The project tested both our flexible manufacturing capability and our local supply chain. Both were up to the challenge and played their part in delivering to the aggressive deadline. Project management, including strict health and safety compliance was also important as all the installs were completed while at the height of the lockdown. We kept the client updated with daily calls and the whole operation ran like clockwork. This demonstrated our ability to flex, adapt and scale our team to fulfil one of our biggest single orders, within one of the shortest lead-times imaginable. But above all, we’re proud to have played our part in helping Morrison’s support their customers through the Covid crisis

The trusted expertise you can rely on.


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