SUCCESS STORIES
The company's distribution network had evolved organically, spreading operations across three buildings and creating excessive travel, additional handling touches, and inefficiencies in picking and staging. A mezzanine configuration further complicated replenishment and material flow, increasing labor effort and operational friction. Limited staging space around painting and refurbishment activities caused congestion and constrained throughput, while the organization also needed a facility strategy capable of safely handling large imaging equipment and efficiently fulfilling high-volume small parts as demand grew and lease deadlines approached.
Alpine designed a consolidated facility layout grounded in a detailed analysis of 12 months of order history to align storage strategies and pick paths with actual demand patterns. The solution introduced clearly defined operational zones based on product characteristics and process requirements, reducing cross-traffic and unnecessary movement. Large equipment was allocated to properly sized floor storage for safe handling, while small and medium items were transitioned to optimized racking systems, with a strong focus on redesigning the high-frequency small-parts picking area to unlock measurable productivity gains.
The engagement delivered a fully executable blueprint to consolidate three facilities into one without disrupting service. The new design doubled refurbishment test bays from three to six, increased paint booth capacity by 30%, and expanded staging capacity by 100%, significantly reducing congestion and improving value-added workflow. Additional 3PL storage created greater service flexibility, and the optimized zoning and racking strategy drove an estimated 25% improvement in small-parts picking productivity. With AutoCAD layouts and a phased move plan in place, leadership gained confidence in a scalable, long-term facility strategy.
