Warehouse design for a medical products manufacturer

PTL Co designed an expanded warehouse operation to consolidate multiple sites, improve flow and provide capacity for future growth.

THE CHALLENGE

Consolidating three operations into one scalable facility

Client

Medical products manufacturer

Sector

Healthcare manufacturing

Scale

Multi-site consolidation; expanded warehouse footprint; future growth capacity

Engagement

Warehouse design

PTL Co helped a medical products business plan the consolidation of three warehouse operations into a more efficient future-state network. The business operated across three sites with duplicated activity, fragmented flows and constraints on future growth. It needed a practical consolidation design that protected service and accommodated different product and handling requirements. The current arrangement also created operational interfaces between locations, reducing visibility and increasing the complexity of inventory movement and control. Before committing to a future model, the client required a clear understanding of capacity, site requirements, warehouse processes and transition implications. The consolidation strategy therefore needed to balance operational efficiency with continuity, ensuring that the proposed design remained workable across the full range of products and service expectations.

3

operations consolidated

50,000 sq ft

new facility

4,400

shelf-picking locations

1,800

reserve pallet locations

WHAT WE DID

Delivery framework

PTL Co profiled the three existing warehouse operations, assessed capacity and handling requirements, and developed consolidation scenarios that brought fragmented activity into a clearer future network model. The work considered how inventory, picking locations, reserve storage, warehouse flows and transition risks would need to interact in a consolidated operation, helping the client understand the practical implications of moving from separate sites to a more integrated facility.

1. PROFILE OPERATION

Analyse volumes, inventory, activity levels and handling needs across each activity being consolidated.

2. MODEL CAPACITY

Calculate future footprint, storage, throughput and support-area requirements so the design reflected projected operational demand.

3. DEVELOP OPTIONS

Create alternative warehouse concepts showing how storage, handling, dispatch, receiving and support areas could be configured.

4. DESIGN FLOWS

Define layout and material movement so separate operational flows connected logically and avoidable interfaces were reduced.

5. PLAN DELIVERY

Set labour, equipment and fit-out requirements to support implementation planning and investment decisions.

WHAT WE ACHIEVED

Outcomes delivered

The business gained a practical consolidation strategy showing how site requirements, storage capacity, warehouse flows and implementation risks could be managed while moving from three separate operations towards a more integrated model. The work gave the client a clearer basis for evaluating the future facility, reducing the risk that consolidation decisions would be made without understanding picking capacity, reserve storage, material movement and transition constraints.

Consolidation design basis.

The future warehouse concept supported multi-site integration by bringing storage, handling, flow and support-area requirements into one coherent operational design.

Defined capacity requirements.

Space needs were aligned to projected volumes and operational activity, giving the client a firmer basis for layout, equipment and future growth decisions.

Improved material flow.

The design clarified movement through the operation, helping reduce avoidable interfaces between activities and align warehouse processes with wider production and service requirements.

Implementation framework.

Labour, equipment and fit-out needs were identified so the proposed design could be translated into a practical delivery plan rather than remaining a high-level concept.

PTL CO EXPERTISE

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Warehouse Design

A well-designed warehouse improves efficiency, maximises capacity and supports operational performance. Effective layouts reduce travel distances, streamline workflows and improve inventory management.
PTL Co helps organisations design practical warehouse solutions that enhance productivity, optimise space utilisation and support future growth.

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