197% More Storage, in the Same Four Walls
A locks manufacturer unlocked 197% additional storage capacity by redesigning vertically and aligning WMS logic with new flow.
+197%
Future storage capacity created
Same footprint
9 m
Vertical height
WMS flow redesigned
System
3-year headroom
Growth
The Situation
Floor-level storage consumed footprint while vertical volume remained largely unused.
Picking paths expanded and the warehouse felt full before true cubic capacity was consumed.
Expansion via additional building space appeared imminent, but existing height was underleveraged.
What We Did
We designed storage and movement together around available building height.
- Engineered vertical storage up to nine metres.
- Redesigned WMS flow to match the new storage model.
- Sized layout and capacity against three-year growth projections.
The Results
The redesign delivered 197% additional storage capacity in the same facility footprint.
The warehouse can absorb projected growth without new construction.
- 01
The cheapest expansion is often the vertical space you already own.
- 02
Before leasing new area, verify whether current area is laid out for flow or just filled.
Industrial Businesses Across 3 Continents