Optimising Brakes UK’s Outbound Logistics Through Warehouse Automation

Engagement and Solution Journey

Bluestonex worked closely with Brakes to uncover these pain points and co-create solutions using Human-Centred Design and Design Thinking. Our team, combining SAP logistics experts, UX designers, and BTP architects, ran a series of workshops with warehouse operatives, administrators, and stakeholders to identify what mattered most.

Rapid prototyping enabled us to test ideas early, gather feedback, and refine solutions quickly. From these sessions, it became clear that automation powered by SAP BTP would deliver the biggest impact.

The solution centred on Maextro, Bluestonex’s configurable data governance automation framework, deployed on SAP BTP. By integrating with Brakes’ existing systems and providing intuitive SAPUI5 applications, we created warehouse tools that worked seamlessly across devices and shifts.

Key steps included:

• Provisioning BTP sub-accounts and deploying secure cloud connectors.

• Building clickable prototypes in Business Application Studio for early user testing.

• Rolling out SAPUI5 warehouse applications in phases across sites.

• Configuring Maextro templates for each plant, ensuring standardisation but allowing for local flexibility.

• Training operatives in under an hour and administrators in a single day—ensuring minimal disruption.

With automation at the core, Brakes moved from manual, error-prone processes to streamlined, intelligent workflows that scaled with demand.

Real Impact Across the Business

The transformation went far beyond technology. By removing unnecessary manual tasks, Brakes gave employees a faster, easier, and more satisfying way of working. Colleagues no longer had to rely on memorising transaction codes or wrestling with clunky interfaces. Instead, they could perform key tasks in just a few clicks.

Operational resilience improved, too. Automation meant Brakes was no longer dependent on small groups of SAP experts, reducing risk while making recruitment and training far simpler. And for the wider business, visibility and control across all distribution centres improved dramatically.

Measuring the Impact

The success of this project can be measured not only in operational efficiencies but also in the tangible business outcomes achieved since implementation:

• A 60–75% reduction in user interactions with SAP screens, significantly decreasing time spent on repetitive, manual tasks.

• An average of 240 administrative hours saved per day since March 2023, equating to substantial cost savings and capacity to focus on value-added activities.

• Training time reduced 26-fold, from six months to just one week, enabling Brakes to onboard new colleagues quickly and adapt to workforce changes with minimal disruption.

• A 100% elimination of data input errors, ensuring higher data integrity and reducing the risk of costly mistakes across the supply chain.

• 300% reduction in administrative staffing costs, made possible by the deskilling of roles and the efficiency of automated workflows.

• A measurable improvement in customer service levels of 0.1% per day across a £2.2 billion operation, demonstrating how internal process efficiencies translate directly to external service improvements.

These results demonstrate the real-world value of warehouse automation. Brakes has not only streamlined its internal operations but also strengthened its ability to deliver on its core promise: ensuring reliable, timely, and high-quality service to customers across the UK.

Looking Ahead

With warehouse automation now embedded in its operations, Brakes has built a foundation for sustainable growth and innovation, beyond its outbound logistics. The company can continue to serve its wide customer base reliably, while ensuring colleagues have the best possible tools to succeed in their roles.

Bluestonex remains a trusted partner on this journey, supporting Brakes as they explore new opportunities to extend automation and strengthen their supply chain further.

Warehouse Automation in Action, six months on

6 months after delivering the solution to the client, we went to visit one of their warehouse sites to see how they were getting on. We were thrilled to see how they were using our Maextro solution to do some of the heavy lifting! Watch the video below to see what they had to say.