Case Study: Store Network Optimization

This case study was authored by Sequoia Partnership, a strategic Optilogic partner specializing in last-mile and supply chain network design.

£42.0m

Annual base cost

£26.1m

Optimized cost

38%

Total reduction

39

Fewer trucks at peak

The Challenge

A national retail operation distributes ambient, chilled, frozen and milk product across hundreds of UK stores from a network of GXO-operated depots.

Annual last-mile cost of £42.0m — driven by 137 trucks at peak, daily delivery windows, and a fleet not matched to drop sizes.

The peak-week network covers 183,000 miles, 4,800 driving hours and over 10,000 hours of unused truck time — significant headroom if routing, frequency and fleet are designed together.

Question: how much cost can be removed without service impact, and which levers matter most?

Our Approach: A Last-Mile Digital Twin

01

Build the twin

Optilogic model calibrated to GXO open-book costs, real road distances (OSRM) and actual store delivery windows.

02

Validate

Reproduce current network cost within 0.2% of actual £42.4m — confirming the model is a true digital twin.

03

Test levers

Quantify the cost impact of routing, frequency, fleet, depot footprint and delivery-window changes — individually and combined.

04

Design programme

Stack the operationally feasible levers into a single transformation programme.

Operational Levers Tested in the Digital Twin

Each lever was modelled independently against the partially-optimized base case (£40.7m) to quantify its contribution. Six categories, fifteen scenarios.

01

Daily route optimization

Replace fixed routebook "bus routes" with daily optimized routing based on actual store volume.

02

Reduced delivery frequency

Cluster stores and consolidate from 6–7 days to 3–4 days using ML clustering + genetic algorithm.

03

Ambient once per week

Aggregate long-life ambient SKUs into a single weekly drop, smoothing in-week peak volume.

04

Delivery-window relaxation

Remove operational (not safety/regulatory) delivery-window constraints at 24% of stores.

05

Fleet optimization

Allow Optilogic to choose vehicle size (7.5T–18T) per route, trading off vehicle, fuel and driver cost.

06

Depot network redesign

8–14 greenfield candidates evaluated from 50 UK locations; brownfield variant retains 8 sites and adds 3.

Quantified Annual Savings by Lever

Savings vs the partially-optimized base case (£40.7m). Levers shown in isolation — they are not additive.

Daily route optimization
£1.3m
Ambient once per week
£2.4m
Reduced delivery frequency
£7.7m
Reduced delivery windows
£3.8m
Fleet optimization
£1.8m
Depot redesign (10 greenfield)
£3.9m
Transformation programme
£11.9m
Transformation + optimized fleet
£14.6m

What the data shows

Reduced delivery frequency is the single largest in-year lever — clustering stores cuts deliveries 23% with no drop in service.

Stacked, the transformation programme delivers £14.6m of annual saving — far more than the sum of the largest individual lever, because depot redesign and frequency changes compound.

Removing milk (–£5.3m) was tested but excluded — the cost of the alternative is unknown.

The Transformation Programme:
£42.0m → £26.1m

What is in the programme:

  • Optimized daily routing replaces fixed routebooks
  • Reduced delivery frequency with clustered stores
  • Ambient deliveries once per week, smoothed across the week
  • Operational delivery-window constraints removed
  • 11 brownfield depots — current 8 plus Coleshill, Newcastle, Southampton
  • Fleet optimized — predominantly 14T vehicles

£42.0m

£28.8m

£26.1m

Base case

Programme

Programme + optimized fleet

Peak-week operational impact

–47%

Driving distance

–45%

Driving time

–27%

Unused truck time

–39

Trucks at peak

Key Takeaways

£15.9m

annual last-mile saving — a 38% reduction in operating cost, without degrading service.

01. Frequency and footprint dominate

Reducing delivery frequency (£7.7m) and redesigning the depot footprint (£3.9m) deliver more than three times the saving of routing optimization alone.

02. A digital twin makes trade-offs explicit

Optilogic was validated to within 0.2% of actual cost, giving the team confidence to test levers — including those that increased some metrics — and stack only the ones that compound.

03. Operational feasibility is the gate

Removing all delivery windows would save £10.8m but is not realistic. The programme keeps safety, regulatory and trading-hour constraints intact.

About Optilogic Partner Sequoia

Sequoia is a 40 year old, specialist supply chain consultancy with deep expertise in network modelling, using advanced optimization and simulation tools to design resilient, cost‑effective distribution networks for clients. The team has delivered network strategy projects for a wide range of organisations, from fast‑growing brands to major multinationals, turning complex data into clear, evidence‑based decisions that are practical to implement.

This case study was authored by Sequoia Partnership, a strategic Optilogic partner specializing in last-mile and supply chain network design.

£42.0m

Annual base cost

£26.1m

Optimized cost

38%

Total reduction

39

Fewer trucks at peak

The Challenge

A national retail operation distributes ambient, chilled, frozen and milk product across hundreds of UK stores from a network of GXO-operated depots.

Annual last-mile cost of £42.0m — driven by 137 trucks at peak, daily delivery windows, and a fleet not matched to drop sizes.

The peak-week network covers 183,000 miles, 4,800 driving hours and over 10,000 hours of unused truck time — significant headroom if routing, frequency and fleet are designed together.

Question: how much cost can be removed without service impact, and which levers matter most?

Our Approach: A Last-Mile Digital Twin

01

Build the twin

Optilogic model calibrated to GXO open-book costs, real road distances (OSRM) and actual store delivery windows.

02

Validate

Reproduce current network cost within 0.2% of actual £42.4m — confirming the model is a true digital twin.

03

Test levers

Quantify the cost impact of routing, frequency, fleet, depot footprint and delivery-window changes — individually and combined.

04

Design programme

Stack the operationally feasible levers into a single transformation programme.

Operational Levers Tested in the Digital Twin

Each lever was modelled independently against the partially-optimized base case (£40.7m) to quantify its contribution. Six categories, fifteen scenarios.

01

Daily route optimization

Replace fixed routebook "bus routes" with daily optimized routing based on actual store volume.

02

Reduced delivery frequency

Cluster stores and consolidate from 6–7 days to 3–4 days using ML clustering + genetic algorithm.

03

Ambient once per week

Aggregate long-life ambient SKUs into a single weekly drop, smoothing in-week peak volume.

04

Delivery-window relaxation

Remove operational (not safety/regulatory) delivery-window constraints at 24% of stores.

05

Fleet optimization

Allow Optilogic to choose vehicle size (7.5T–18T) per route, trading off vehicle, fuel and driver cost.

06

Depot network redesign

8–14 greenfield candidates evaluated from 50 UK locations; brownfield variant retains 8 sites and adds 3.

Quantified Annual Savings by Lever

Savings vs the partially-optimized base case (£40.7m). Levers shown in isolation — they are not additive.

Daily route optimization
£1.3m
Ambient once per week
£2.4m
Reduced delivery frequency
£7.7m
Reduced delivery windows
£3.8m
Fleet optimization
£1.8m
Depot redesign (10 greenfield)
£3.9m
Transformation programme
£11.9m
Transformation + optimized fleet
£14.6m

What the data shows

Reduced delivery frequency is the single largest in-year lever — clustering stores cuts deliveries 23% with no drop in service.

Stacked, the transformation programme delivers £14.6m of annual saving — far more than the sum of the largest individual lever, because depot redesign and frequency changes compound.

Removing milk (–£5.3m) was tested but excluded — the cost of the alternative is unknown.

The Transformation Programme:
£42.0m → £26.1m

What is in the programme:

  • Optimized daily routing replaces fixed routebooks
  • Reduced delivery frequency with clustered stores
  • Ambient deliveries once per week, smoothed across the week
  • Operational delivery-window constraints removed
  • 11 brownfield depots — current 8 plus Coleshill, Newcastle, Southampton
  • Fleet optimized — predominantly 14T vehicles

£42.0m

£28.8m

£26.1m

Base case

Programme

Programme + optimized fleet

Peak-week operational impact

–47%

Driving distance

–45%

Driving time

–27%

Unused truck time

–39

Trucks at peak

Key Takeaways

£15.9m

annual last-mile saving — a 38% reduction in operating cost, without degrading service.

01. Frequency and footprint dominate

Reducing delivery frequency (£7.7m) and redesigning the depot footprint (£3.9m) deliver more than three times the saving of routing optimization alone.

02. A digital twin makes trade-offs explicit

Optilogic was validated to within 0.2% of actual cost, giving the team confidence to test levers — including those that increased some metrics — and stack only the ones that compound.

03. Operational feasibility is the gate

Removing all delivery windows would save £10.8m but is not realistic. The programme keeps safety, regulatory and trading-hour constraints intact.

About Optilogic Partner Sequoia

Sequoia is a 40 year old, specialist supply chain consultancy with deep expertise in network modelling, using advanced optimization and simulation tools to design resilient, cost‑effective distribution networks for clients. The team has delivered network strategy projects for a wide range of organisations, from fast‑growing brands to major multinationals, turning complex data into clear, evidence‑based decisions that are practical to implement.

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