Making Do With What You Have

A case study on creative problem-solving

A foodservice distribution client faced a common challenge many businesses encounter— a warehouse operating at maximum capacity. To add to the complexity, the site's layout was far from ideal, characterized by irregular shapes and a significant slope that drove construction costs through the roof. Our task? Think outside the box and craft actionable solutions that addressed these operational constraints.?

This meant looking at zoning areas and aisles differently from the more common I-Shaped or L-Shaped configurations we see in most warehouses.??

For example: while both parties agreed to incorporate warehouse automation, constraints on available space necessitated a strategic trade-off. The challenge was to balance the desire for more expansive automation solutions with the need to reserve prime space for fast-moving SKUs. Due to space limitations, the decision was made to position automation behind the refrigerated section, resulting in increased travel distances. Balancing operational efficiency against traditional design costs presented a daunting puzzle to solve, but it just took a little bit of elbow grease.?

By reconfiguring existing spaces, extending into adjacent areas, and reshaping our design approach, we uncovered a solution that not only met the requirements but also aligned with practicality. While this project dates back a couple of years, it stands as a testament to leveraging innovation when faced with challenges. The client’s strategic decision to maximize existing resources instead of investing in a new site showcased a shrewd financial strategy that took into consideration designing operations volumetrically and vertically.?

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As land prices continue to increase and organizations seek to optimize their network with more strategically placed distribution centers, the traditional method of sourcing land, designing the warehouse to fit the land and then designing the components of the warehouse is less and less effective. We can take lessons from the experience with this food distribution company and designing from the inside-out. By defining the warehouse task first, then designing the infrastructure, processes and systems required to meet the requirements, you can value engineer your facilities and achieve more innovative solutions.?

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Stay tuned for more #JeffOnSite posts where we'll continue sharing firsthand perspectives from the field of supply chain operations. Questions? Reach out to us (or Jeff directly) today!

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