Layout Optimization for Consumer Goods Distribution Center

Client Type: Consumer Goods distributor operating multiple distribution sites

Challenge: Existing warehouse layout led to congestion in high-volume aisles and underutilized rack zones. The goal was to increase pallet capacity and improve flow without new construction.

Approach:
Nikswap Solutions conducted a layout reconfiguration study, analyzing SKU velocity, pallet movements, and aisle travel.
We:

• Recommended converting selective racks to case flow and pallet flow in fast-moving zones

• Optimized replenishment and picking paths

• Modeled before-and-after FTE and travel distance impacts

• Produced revised AutoCAD layouts and implementation sequencing

Result:
Achieved a 15% increase in storage capacity, a 12% improvement in pick productivity, and deferred major capital investment for at least 3 years.