SUCCESS STORIES
A global manufacturer of high-performance sporting goods, recognized for its innovation, product quality, and strong presence across both professional and consumer markets makes premium equipment and offers apparel, accessories, and customized services to support athletes and enthusiasts at all skill levels. As the organization prepared for aggressive multi-year growth and significant changes to its manufacturing and distribution footprint, it reached out to Alpine Supply Chain Solutions to support warehouse optimization and future-state facility design.
The client’s existing warehouse network and infrastructure could not support aggressive five-year growth across multiple product lines. New distribution facilities and the return of overseas assembly added complexity to labor planning, storage, and service levels. Inefficient layouts and storage strategies limited productivity and increased replenishment frequency. Without a scalable, standardized design, the organization risked higher costs and missed customer SLAs as volumes grew.
Alpine applied its warehouse optimization methodology, starting with a best-practice assessment to identify operational gaps and future requirements. The team conducted a detailed storage type analysis and developed multiple future-state CAD layouts to improve flow, density, and throughput. A crawl-walk-run-fly automation strategy evaluated options including AMRs, Pick-to-Light, and Goods-to-Person systems. Each solution was assessed for ROI, scalability, and alignment with a future WMS.
The optimized warehouse designs delivered significant operational improvements while positioning the organization for scalable growth. Storage density increased by 45%, while replenishment frequency was reduced by 86% at one site and 68% at another, driving meaningful labor productivity gains. Standardized storage and improved slotting reduced manual handling and improved service level performance. Automation evaluations identified four scalable solutions with payback periods under seven years and projected ROIs of 2x–6x, providing a clear roadmap for phased investment aligned to five-year growth plans.
