SUCCESS STORIES
A biotechnology and medical device producer committed to advancing global health manufactures high-quality products for medical, scientific, and research applications. As demand for its life-changing technologies continued to rise, the organization faced mounting operational challenges in its warehouse related to limited space, inefficient material flow, and labor-intensive processes. To improve storage capacity, streamline workflows, and prepare for future automation, the company partnered with Alpine Supply Chain Solutions to redesign its warehouse for higher performance and long-term scalability. Key Challenge
Severe space constraints, inefficient material handling, and a fragmented warehouse layout limited the company’s ability to scale. Excessive manual touches, long travel paths, and poor FIFO control increased labor costs and risked product quality. With demand accelerating, the organization needed a layout that improved throughput while supporting future automation.
Alpine led a 6–8 week engineering and design engagement, evaluating multiple layout options to maximize capacity, efficiency, and automation readiness. The final design expanded storage capacity with high-density pallet shuttle systems, improved FIFO control, and established one-way material flow paths. Strategic slotting, ergonomic improvements, and AGV-ready travel lanes reduced unnecessary motion and positioned the facility for automation.
The redesigned warehouse increased overall storage density by 29%, with select areas achieving up to 37% capacity gains. Material flow, FIFO compliance, and labor efficiency improved through streamlined layouts and reduced manual handling. The facility is now automation-ready, providing a scalable foundation for future AGV deployment and continued operational growth.
