Warehouse Layout and Flow Optimization

TriVista optimized the layout of a 50,000 sq. ft. warehouse for a leading consumer products company

The Challenge

A private equity owned consumer products importer wanted to improve warehouse efficiencies, reduce material movement and improve product flow inside their new 50,000 sq. ft. facility. TriVista was retained to design an optimized facility layout and make recommendations to improve product flow that would ultimately reduce movement, reduce labor costs and ease the transition into the new facility.

Our Approach

TriVista’s team of warehouse operations experts led a focused, 2 week diagnostic and improvement project with warehouse management and the executive team. Using the DMAIC (Define, Measure, Analyze, Improve, Control) Process, supported by other Lean and Six Sigma tools, we were able to rapidly identify where the excess material movement was flowing. Once the issues were understood, costs were calculated. TriVista began to design an optimized facility layout for the new warehouse. Upon completion of the optimized design, our team set up control mechanisms to ensure that warehouse management and personnel would be able to implement and sustain the improvements.

The Results

TriVista’s client was extremely satisfied with the results. Our two week project netted more than $200,000 USD in annual savings to the company and was hailed as a significant improvement to their current state.