The Challenge
A new client came to us with an empty 16,000 sq ft warehouse that needed a complete outfitting. Their primary goal was to transform the space into a fully operational and efficient logistics hub. They required a comprehensive design that would maximize pallet storage capacity while ensuring strict safety standards and a streamlined workflow.
Our Solution
We approached this project with a detailed, phased methodology to ensure every aspect of the warehouse setup was optimized for long-term success.
1. Strategic Planning & Racking Selection We began with an in-depth analysis of the client’s inventory, including item weight, size, and SKU volume. This foundational step allowed us to design a truly tailored solution. We selected a conventional racking system to ensure 100% accessibility and focused our design on optimizing cubic utilization, providing a significant increase in total pallet positions.
2. Expert Forklift and Equipment Recommendations Our recommendations were not based on generic specifications but were the result of a rigorous analysis of multiple different forklift options. We cross-referenced critical data points from our layout design, strategically selecting an aisle width that was within the most compact 20% of the market range. This choice maximized the number of aisles and significantly increased floor space utilization. We also chose a lift height that precisely matched the building’s vertical capacity, ensuring no over-investment. The final selection achieved approximately 67% cost-saving compared to the most expensive option considered. This strategic choice provided the client with a high-performing, reliable asset that perfectly fit their budget.
3. Data-Driven Supplier Selection To ensure the client received the best possible value without compromising on quality, we conducted thorough supplier research. We built a detailed matrix to compare different vendors on critical factors like technical specifications, pricing, and lead times. This data-driven approach allowed us to identify the most reliable and cost-effective partners, resulting in a final investment that was 44% more efficient on a per-pallet basis than the most expensive option.
4. Comprehensive Project Management & Documentation To guarantee a smooth and timely launch, we developed a detailed GANTT chart to guide the entire project. This plan, spanning for around 4 months to the final operational start, provided a clear roadmap for all key phases, including:
- Initial project definition and data collection.
- Supplier selection and the installation of all racking, trucks, and warehouse materials.
- Setup of all essential utilities, IT connections, and safety protocols.
- Final staff training and site certification to ensure all personnel were ready for the launch. This proactive documentation ensured a clear path to operational readiness.
The Outcome
By delivering a meticulously planned and expertly executed design, we provided the client with a robust, scalable, and highly efficient warehouse. Our data-driven approach to equipment and supplier selection provided a 44% more cost-effective solution overall. Our comprehensive project plan and proactive management enabled a seamless transition from an empty space to a fully operational facility, ensuring the client’s new logistics hub was prepared for both current needs and future growth.
Operations Management Services
Discover how our tailored operations management services can help you improve the operational performance of your organization.
Subscribe to our newsletter
Join our community of like-minded Operational Excellence enthusiasts and subscribe to our newsletter for the latest trends, expert insights, and exclusive content delivered straight to your inbox. Let’s connect, explore and discover excellence in every step.
