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Warehouse Design & Layout Consulting

Better Warehouse Layout.Lower Operating Costs.

We redesign flow, storage, and picking paths around how your warehouse actually operates — not how it was originally set up.

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500+

Clients Served

12+

Years

40+

Sectors

1M+

Man Hours

Full-time on-site consultants

Shop floor execution, not just advisory

Results embedded into daily operations

Serving India, Middle East, and SE Asia

What We Solve

Why Your Warehouse Isn't Moving Faster?

Hidden Layout Issues Are Slowing Every Warehouse Operation

Most warehouses don't run out of space — they lose productivity because warehouse layouts, storage systems, and material flow were never designed for operational efficiency.

01

Limited Storage Capacity

Warehouse space appears full even though significant storage potential remains unused.

We analyse storage utilization, redesign warehouse layouts, and optimize storage strategies to increase effective capacity.

Result: Up to 38% improvement in warehouse space utilization.

02

Poor Utilization of Vertical Space

Storage is concentrated at floor level while available warehouse height remains underutilized.

We evaluate storage profiles, optimize rack design, and maximize vertical storage opportunities.

Result: Increased storage capacity without warehouse expansion.

03

Congested Warehouse Movement

Forklifts, operators, and material movement compete for the same space, creating delays and inefficiencies.

We redesign warehouse layouts, aisle configurations, and movement paths to improve flow.

Result: Faster warehouse movement and reduced operational congestion.

04

Unstructured Storage Locations

Inventory placement evolves over time without clear slotting logic, making storage and retrieval slower.

We implement warehouse zoning, slotting strategies, and inventory placement standards.

Result: 50% increase in warehouse productivity through improved storage flow.

05

Excessive Travel Distances

Materials travel longer distances than necessary, increasing handling effort and operational cost.

We optimize warehouse flow, picking routes, and storage locations to minimize travel.

Result: 41% reduction in material handling touchpoints.

06

Inadequate Racking Systems

Existing storage infrastructure may no longer match inventory profiles or business requirements.

We evaluate rack utilization, inventory characteristics, and storage requirements to design the right racking strategy.

Result: Improved storage efficiency and faster warehouse operations.

Proven Results

Results We Delivered

FMCG Distribution Warehouse

60% Faster Dispatch Operations

  • Improved staging and dispatch flow
  • Reduced loading delays
  • Faster outbound vehicle turnaround
  • Achieved within 4 months

Automotive Warehouse

38% Improvement in Warehouse Space Utilization

  • Optimized warehouse rack layout
  • Improved warehouse zoning
  • Increased storage capacity without expansion
  • Achieved within 5 months

E-commerce Fulfilment Centre

50% Increase in Warehouse Productivity

  • Reduced picker travel distance
  • Improved warehouse slotting strategy
  • Faster warehouse workflows
  • Achieved within 6 months

Pharma Distribution Warehouse

41% Reduction in Material Handling Touchpoints

  • Streamlined warehouse material movement
  • Reduced double handling
  • Improved warehouse storage flow
  • Achieved within 4 months
Our Method

The Gemba Approach

01

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.

02

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.

03

Current state mapping & baseline

Every process mapped in detail. A signed performance baseline established — the reference point against which every improvement is measured.

04

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.

05

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.

Industries We Serve

Experience Across Diverse Industries

We have supported manufacturers across:

AutomotiveAuto ComponentsPharmaceuticalsLife SciencesFMCGConsumer GoodsEngineeringIndustrial ManufacturingChemicalsProcess IndustriesPrintingPackagingTextileApparelSolarRenewable Energy
Client Voices

What operators say after we leave.

“Redesigned operations and a new warehouse system brought significant improvement to our distribution centre.”

Nandish Gulecha

Managing Director

Kushal's Retail Pvt Ltd

Fashion Jewellery Retail · India

NG
“Exceptional expertise in reducing bottlenecks, optimizing stock movement and data-driven inventory management.”

Sanjeev Wangoo

Executive Director – Supply Chain

Veedol Corporation Limited

Lubricants & Automotive Solutions · India

“A structured, data-driven approach that lifted production, quality, maintenance and planning across both plants.”

Neeraj Ganglani

Director

Neeraj International & Neeraj Plastics

Plastics & Packaging · Middle East

NG
“Exceptional lean expertise that reduced operational inefficiencies and streamlined our warehouse management practices.”

Rahul Agarwal

COO

Mahalakshmi Profiles Pvt Ltd

Steel & Tubes Manufacturing · India

“Strong cross-functional collaboration and viable solutions make them recognized process-driven experts.”

Harjiv Swani

Director – Operations

Swani Spice Mills Pvt Ltd

Spice Manufacturing · India

“Committed execution support — we confidently recommend them for operational excellence projects.”

Mukesh Thakkar

Managing Director

Gita Hospitality Pvt Ltd

Hospitality · India

MT
Trusted by Industry
500+

Industrial Businesses Across 3 Continents

Frequently asked questions

Let's Talk

Ready To Recover Lost Warehouse Productivity?

Every inefficient movement and poor layout reduces warehouse productivity. Optimize your warehouse flow, maximize space, and improve operational performance.

No commitment. A focused 30-minute conversation.

Speak directly with a senior operations consultant.

Specific inputs based on your warehouse constraints.

Response within 24 hours.

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