WÜSTHOF Store Solingen mit Holzregalen voller Messer und einem Holztisch mit Messern und Pflanzen in modernem, hell beleuchtetem Innenraum

Success Story

Restructuring of Packaging and Shipping Logistics

WÜSTHOF is restructuring its packaging and shipping logistics for 2030

Standardization of packaging, optimized material flows, and a practical vision for the Solingen site

A new packaging concept at WÜSTHOF reduces the complexity of packaging for individual knives from approximately 97 types of outer packaging to a standardized system with seven sizes. However, the existing logistics system was not designed to handle this fundamental change.

Based on this, Rothbaum developed an integrated vision for the packing room, warehouse, order fulfillment, material flow, and organization. Redesigned workstations, the combined handling of cutting and packaging, and the integration of labeling lay the groundwork for efficient implementation.

The result is a scalable packaging and shipping logistics system through 2030—with more efficient use of space, clear processes, and no projected need for additional staff.

Portrait of Klaus Willmann

With the jointly developed vision, we have established a clear and robust foundation for making our packaging logistics more efficient, making better use of space, and taking a structured approach to the next steps in implementation.

Klaus Willmann, Chief Operating Officer (COO), WÜSTHOF GmbH

From Complex Packaging Processes to Scalable Logistics

Challenge

WÜSTHOF faced the challenge of aligning its packaging and shipping logistics with the volumes projected through 2030. High levels of manual labor, long distances, limited space, and approximately 97 different types of outer packaging led to a high degree of complexity. At the same time, the logistical foundations for the new, standardized packaging concept had to be established.

Implementation

Rothbaum analyzed processes, data, and material flows and, in collaboration with WÜSTHOF, developed an integrated vision for the packing room, warehouse, order fulfillment, and shipping. To this end, the layout, warehouse concept, transport logic, workstations, and organization were aligned with the new packaging concept and translated into ten coordinated measures.

Results

The vision that has been developed lays the groundwork for implementing the new packaging concept and establishing a scalable logistics system by 2030. Standardized packaging, optimized space and material flows, and a new staging and role-based system will enable the planned growth without the need for additional staff.

88 %

addressed the vulnerabilities that require action

~97→7

Packaging Options for Individual Knives

3 FTE

Additional staffing needs avoided through 2030

Detailed Results

  • Logistical implementation of the new packaging concept through a modified packing area, material staging, material flows, and organization
  • Development of a coordinated target layout across all levels to make more efficient use of existing space
  • Increasing storage capacity through a new storage concept and reclaiming space that had previously been used for other purposes
  • Reducing manual trips and transport by providing knives and packaging together and clearly defining roles
  • Cost-Effective Automation: A Hybrid Warehouse Solution Instead of Unprofitable Full Automation
  • Ten coordinated implementation measures, including an investment estimate and a prioritized 10-month roadmap
Rothbaum-Success-Story-Packaging-and-Shipping-Logistics-Wüsthof
Portrait of Philipp Kappus.
Philipp Kappus

Senior Production Manager

Feel free to contact me!

Do you have questions about the success story or about optimizing a packaging concept? Or do you have a specific project inquiry? Send me a message, and I’ll get back to you right away.

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