Up to 197%
Additional Storage Capacity Created
Unlock more storage from the same warehouse footprint.
Warehouse Design & Layout Consulting
Many manufacturers believe they need more warehouse space when, in reality, they need a better warehouse design.
We help manufacturers optimize layouts, storage density, and material flow to unlock hidden capacity, reduce handling costs, and improve operational performance.
India | Middle East | Africa
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Results Section
What You Gain
Up to 71%
Space Utilisation Improvement
Improve storage density and warehouse organization.
Up to 3×
Vertical Space Utilisation
Maximize available building height for storage.
Up to 43%
Storage Footprint Reduction
Store more inventory in less floor space.
Up to 68%
Turnaround Time Reduction
Faster receiving, putaway, picking, and dispatch operations.
Zero
Layout Rework During Implementation
Validated designs that minimize costly changes during execution.
Pain Point Section
Is Your Warehouse Running Out of Space or Running Out of Efficiency?
Limited storage capacity
Warehouse space appears full even though significant storage potential remains unused.
Poor utilization of vertical space
Storage is concentrated at floor level while available warehouse height remains underutilized.
Congested warehouse movement
Forklifts, operators, and material movement compete for the same space, creating delays and inefficiencies.
Unstructured storage locations
Inventory placement evolves over time without clear slotting logic, making storage and retrieval slower.
Excessive travel distances
Materials travel longer distances than necessary, increasing handling effort and operational cost.
Inadequate racking systems
Existing storage infrastructure may no longer match inventory profiles or business requirements.
Capacity constraints limiting growth
Warehouse layouts designed for current volumes struggle to support future expansion.
Expensive warehouse expansion decisions
Additional warehouse space is often considered before existing capacity has been fully optimized.
Solution Section
Where We Help You Succeed
Warehouse Capacity Planning
Calculate storage requirements based on inventory volumes, throughput, and growth projections.
Storage System Design
Select the most suitable racking and storage systems based on product characteristics and operational requirements.
Vertical Space Optimisation
Increase storage capacity by effectively utilizing available warehouse height.
Warehouse Layout Design
Develop optimized 2D and 3D warehouse layouts to improve storage density and operational flow.
Material Flow Optimisation
Reduce unnecessary movement and improve receiving, storage, picking, and dispatch efficiency.
MHE Planning & Selection
Identify the right material handling equipment to support warehouse performance and storage strategies.
Slotting & Location Management
Implement structured location coding and slotting systems for improved inventory control and picking efficiency.
Future Expansion Planning
Design scalable warehouse layouts that support long-term business growth.
Digital Warehouse Intelligence
Real-Time Inventory Visibility & WMS
Real-time inventory visibility, QR based putaway, intelligent slotting and live stock accuracy — all on one WMS platform designed to sustain warehouse performance.
See How It Works the PlatformCapacity
+197%
additional storage created
Space Utilisation
+71%
improvement
Footprint
−43%
storage reduction
Turnaround
−68%
time reduction
Our Approach
The Gemba Approach
A proven 5‑phase methodology delivered on your shop floor — not from a boardroom. Every phase is hands‑on, data‑backed, and measured against a signed baseline.
Assessment & diagnostics
A 2–4 day on-site study. We walk your floor, observe your processes, and find where time, output, and cost are quietly being lost.
Scope, deployment & commercials
Scope defined from your data, not a template. Commercials built on a clear ROI case, so the decision to proceed is grounded in numbers.
Current state mapping & baseline
Every process mapped in detail. A signed performance baseline established — the reference point against which every improvement is measured.
Proof of concept, implementation & on-site training
Solutions validated on the floor before full rollout. Implementation happens alongside your team. Training happens at the Gemba in real conditions, under real pressure.
Sustenance & audit handover
Review systems and audit structures built into your team before we step back. We do not exit on a deadline. We exit when the results hold.
We don't exit on a deadline. We exit when the results hold.
Every engagement includes audit handover and built‑in review systems.
Case Studies Section
Featured Case Study
Real project outcomes across warehouse operations, with measurable storage capacity gains and sustained layout improvements.
Locks Manufacturing & E‑commerce
197% Future Storage Capacity Created
A locks manufacturing and ecommerce business storing pallets at ground level, leaving most of its height unused. By designing for vertical storage up to nine metres and redesigning the WMS flow, the warehouse created 197% additional capacity and became a future-ready facility built to serve three years of growth.
197% additional storage capacity9-metre vertical storage3-year growth-ready facility
Key Levers
- Vertical storage design (up to 9m)
- WMS flow redesign
- Racking system specification
- Future-proof layout planning
Industrial Packaging
Raw Material Storage Cut from 50,000 to 38,000 Sq Ft
A Fortune 1000 packaging operation needed a layout designed for five years of growth. Through value stream mapping, capacity evaluation, and a U-shaped flow with selective and cantilever racking, raw material storage was reduced from 50,000 to 38,000 square feet while production rose from 12 to 25 boxes per shift.
12,000 sq ft storage reduction12 → 25 boxes/shift5-year growth-ready layout
Key Levers
- Value stream mapping
- Capacity evaluation
- U-shaped flow design
- Selective & cantilever racking
Frequently Asked Questions (FAQ's)
Common Questions, Clear Answers
Everything companies usually ask before starting a Warehouse Design & Layout engagement.
What is Warehouse Design & Layout?
Warehouse Design & Layout focuses on optimizing storage capacity, material flow, racking systems, and operational efficiency within a warehouse. The objective is to maximize usable capacity while improving warehouse performance.
Do we need a larger warehouse if we are running out of space?
Not always. Many warehouses can significantly increase storage capacity through better layout design, vertical space utilization, and optimized storage systems before considering expansion.
Do you design new warehouses as well as improve existing facilities?
Yes. We support both greenfield warehouse design projects and optimization of existing warehouse operations.
What deliverables are included in a warehouse design project?
Deliverables typically include capacity calculations, storage strategy recommendations, racking specifications, 2D and 3D layouts, material flow design, slotting logic, and implementation roadmaps.
How do you ensure the warehouse design will work?
Designs are validated using actual inventory data, throughput requirements, site measurements, and operational constraints before implementation begins.
Which industries benefit from Warehouse Design & Layout?
Manufacturing, FMCG, Packaging, Building Materials, Engineering, Automotive, Ecommerce, Retail Distribution, Chemicals, and industrial warehousing operations can all benefit from warehouse design and layout optimization.
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