Facility Layout & Warehouse Design

Maximize Your Warehouse and DC Productivity, Profitability and Adaptability

Needed improvements are not always obvious. And, if they are, sometimes they require a deeper look to ensure that proposed technology upgrades and process changes will adequately address the issues at hand. Through an assessment of existing “brownfield” or new “greenfield” locations, we’ll show you just how your facility will operate with automation changes, demonstrate process flows, discuss material handling techniques, and highlight operator interfaces.

Armed with the latest data tools as well as simulation software, Bastian Solutions consultants and engineers not only design efficient systems but also understand the technical components going into them.  This  allows us to propose appropriate solutions with execution roadmaps that offer confidence in your investment and keep your business goals in mind at all times. Our team of supply chain consultants work alongside you, providing guidance throughout the project.

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Common Warehouse & Facility Challenges

New advanced technologies in material handling and supply chain automation plus changing business goals and market fluctuations can often trigger evaluation of operations and business plans. For some of our customers, however, reviews are also initiated by warehouse or distribution center constraints, specific industry requirements and supply chain process challenges.

In general, some automation solution considerations that our consultants commonly see across industries include:

  • Strained manual operations (e.g. order fulfillment picking)
  • Long or inconsistent order fulfillment or manufacturing timeframes
  • Limited warehouse facility space
  • Changes in industry requirements
  • Errors or inconsistencies in manufacturing or order fulfillment
  • Increasing overhead and operating costs
  • Transition to new automated solutions

Engaging Bastian Solutions allows you to consider your warehouse or distribution center facility processes from the perspective of your product, process flows, material handling techniques, operator interfaces, and plant structures. Profiling the current movement of product and projecting material flow help you design the best building and material handling system to accomplish your company’s goals.


Operations Assessment & Engineering

In all reviews, Bastian Solutions experts work with you to understand small and big picture details about your company, industry and operations. We’ll perform a deep dive into the challenges and identify appropriate material handling or order fulfillment automation system solutions.

Operations Assessment

Using tested methods to identify improvements, our material handling consultants perform an extensive review of product flow, order fulfillment and distribution processes to identify and provide recommendations that will lead to immediate benefits. As part of the Bastian Solutions operations assessment, an in-depth study is also performed to determine if more involved changes are necessary.

Operations Engineering

Sometimes shorter in duration and lower in cost, a supply chain or material handling operations engineering review is a focused study to solve a specific material or product handling operational problem. Like an operations assessment, recommendations are provided based on thorough assessment of inefficiencies. Advice is provided to assist with change in:

  • Management
  • Technology
  • Equipment
  • Employee training
  • Process and systems improvements

Developing an Effective System Operations Plan

Whether you are building a new warehouse or distribution center facility, exploring a new system, or wanting to improve current operations, Bastian Solutions consultants work with customers in four crucial areas:

Define and Measure the Process – Bastian Solutions engineers work directly with project stakeholders to determine project objectives, understand company operations, identify challenges and risks, and develop quantitative and qualitative criteria to evaluate final recommendations.

Analyze the Data – Understanding the data inside-and-out, and how it affects the current operation and the recommended design is vital. Bastian Solutions engineers analyze the data from your operating systems and create data models to predict future states. It is from this information that design parameters are determined. Data analysis often includes review of order profiles, order types and patterns, seasonality, and SKU profiles.

Layout and Design - It is only after the critical steps above are completed that engineers begin to “put pencil to paper.” In the design phase, armed with CAD 3D software, recommendations are produced with detailed descriptions of operations, including flow charts, labor requirements, slotting analysis, annotated drawings and narratives to describe how the new system will work and how it will meet the criteria identified in the define and measure process.

Validate - The estimated cost and benefits of each recommendation are quantified and compared in the validation phase. Estimated project schedules are created to evaluate the alternatives’ effect on the time frame requirements. Using a decision matrix approach, a solution is recommended and presented to the client.


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