Warehouse Layout Optimization for Increased Storage Capacity

This case study details the collaboration between Hy-Capacity and Alpine Supply Chain Solutions to address significant space constraints in Hy-Capacity's warehouse. The document outlines the challenges faced by Hy-Capacity due to a lack of storage and the need for an improved facility layout. Alpine conducted a thorough Storage Type Analysis (STA) using advanced algorithms and Optricity’s OptiSlot software to determine optimal storage configurations. The STA involved multiple phases, including data review and site visits, to develop tailored storage and rack profiles. Additionally, an ABC analysis was performed to categorize inventory based on demand and cost, which informed the layout design. The resulting new layout expanded the warehouse from three zones to four and increased storage capacity by 85 percent, allowing Hy-Capacity to delay moving to a new facility by two years. The implementation of the new layout is being executed in phases to minimize disruption to ongoing operations.