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Warehouse Design & Optimization

Design physical systems, evaluate operating alternatives and implement control.

Configure warehouse layouts and storage, compare performance scenarios, align stock records with the floor, and connect warehouse replenishment to production. Start with a defined problem or the evidence from an audit.

  • Warehouse Layout Design
  • Warehouse Simulation & Digital Twin
  • Inventory Accuracy & Control
  • Line Feeding & Plant Stores Design
Discuss your warehouseView technical scope
60 × 36 m envelope; 2.4 m rack rows and 3.6 m aisle gaps. Dimensions are illustrative.
DE-01 / Vector drawing

Dimensioned warehouse layout

100%

60 × 36 m envelope; 2.4 m rack rows and 3.6 m aisle gaps. Dimensions are illustrative.

Building, fire egress, floor loading, services and equipment access require project-specific engineering review.

Open original asset ↗

Explore the engineering services.

Service B1 · Layout, storage and capacity design

Warehouse Layout Design.

Congested storage, difficult access, growing inventory, or an upcoming expansion or relocation.

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[ What we engineer ]

The technical scope.

Each service is scoped to the problem. These are the areas it typically covers.

  1. B1
    Original illustrative 60 by 36 meter warehouse layout with dimensioned rack rows and clear aisles

    Warehouse Layout Design

    Congested storage, difficult access, growing inventory, or an upcoming expansion or relocation.

    Scope, approach & deliverables : Warehouse Layout Design

    What we engineer

    • Internal warehouse layout engineering
    • Storage system selection
    • Racking configuration and capacity planning
    • Aisle and equipment compatibility
    • Narrow and very narrow aisle feasibility
    • Receiving, picking, kitting and dispatch zones
    • Dock positioning and staging requirements
    • Material-flow planning
    • SKU slotting
    • Conceptual master planning
    • Expansion and reconfiguration planning
    • Racking and equipment specification support
  2. B2
    AI-generated conceptual warehouse render with racks, pallets, clear aisles and a forklift

    Warehouse Simulation & Digital Twin

    You need to compare layouts, staffing levels or automation options under normal and peak demand before committing resources.

    Scope, approach & deliverables : Warehouse Simulation & Digital Twin

    What we engineer

    • Warehouse process modeling
    • Layout scenario comparison
    • Discrete-event simulation of flows and queues (AnyLogic)
    • Robotics and AMR fleet simulation (NVIDIA Isaac Sim)
    • Resource utilization analysis
    • Travel and congestion analysis
    • Capacity and throughput scenarios
    • 2D/3D design visualization
    • Automation and robotics feasibility
    • Simulation-assisted decision support
  3. B3
    Warehouse staff verifying inventory in a storage area

    Inventory Accuracy & Control

    Stock is difficult to locate, physical quantities disagree with records, or replenishment repeatedly fails.

    Scope, approach & deliverables : Inventory Accuracy & Control

    What we engineer

    • Inventory accuracy
    • ERP/WMS against physical inventory reconciliation
    • Receiving and put-away controls
    • Location management
    • Labeling and identification
    • Cycle counting
    • Inventory traceability
    • 5S and visual management
    • Shortage prevention
    • WMS functional assessment and requirements
    • SOP development
  4. B4
    Production parts in organized bins with a physical kanban replenishment card

    Line Feeding & Plant Stores Design

    Production waits for materials, kits arrive incomplete, or excess stock accumulates beside the line.

    Scope, approach & deliverables : Line Feeding & Plant Stores Design

    What we engineer

    • Warehouse and production synchronization
    • Kitting systems
    • Point-of-use material availability
    • Replenishment processes
    • Supermarket design
    • Kanban and pull systems
    • Material presentation
    • Shortage visibility
    • Production schedule alignment
    • Line-side inventory control

[ Supporting capabilities ]

Built into the services.

These are not separate products. They are delivered as part of the services they support, scoped to what your project needs.

[ Not sure where to start? ]

Start with the evidence.

If you don’t yet know whether the problem is the building, the layout or the process, a Facility Audit establishes the baseline the engineering work builds on.

Warehouse Audits

Start here

Let’s engineer
your warehouse.

Expansion, re-layout, an automation decision, stock you can’t trust or a line waiting for parts. Tell us what you’re planning and we’ll show you where engineering helps.

Plan a Warehouse RedesignSee our approach