Warehouse Layout and Capacity Concept for a Fast-Growing Cosmetics Manufacturer
The Challenge
The company was growing 40–80 percent a year, which had exhausted its warehouse space and pushed operations onto two working levels. The variety of orders and sharp volume spikes made work organization difficult, and planning processes couldn't keep pace with the scale.
What We Do
A diagnostic workshop and interviews with management and warehouse leadership.
Development of conceptual warehouse layouts and material flow diagrams.
Calculation of warehouse capacity broken down by zone and storage location type.
Diagnosis of planning and inventory management processes.
Results
Storage capacity increased by roughly 45 percent, from around 200 to 289 pallet positions.
Roughly PLN 26 million of frozen capital identified in inventory.
Roughly PLN 3 million of inventory with turnover of over a year flagged for reduction.
Summary
A conceptual warehouse layout was developed together with a capacity calculation, material flow design, and budget, substantially increasing the number of pallet positions. In parallel, directions were identified for improving inventory management and planning, laying the foundation for further scaling of operations.
