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.
Strategic Takeaway
- The cheapest expansion is often the vertical space you already own.
- Before leasing new area, verify whether current area is laid out for flow or just filled.
Contact Gemba Concepts
Need Help Solving Similar Execution Gaps?
Connect with our consulting team to discuss your current operational challenge and the outcomes you want to achieve.
Bengaluru
Ram Leo, 59/4, Market Rd, Basavanagudi, Karnataka 560004
Ahmedabad
World Trade Tower, Near Sarkhej Sanand Cross Road, Gujarat 380051
Share This Article
Found this useful? Share it with your team and peers.
