Warehouse Layout and Slotting Design

Parts distributor transitions a distribution center with an optimized forward-pick area.

A parts distributor engaged SCPI to design an optimized forward-pick layout and slotting plan ahead of a fast-approaching distribution center transition, where inconsistent SKU data and undefined storage needs threatened go-live readiness.

This project produced a greenfield slotting model covering refined line activity in the forward-pick area and enhanced active inventory cube, with tailored storage media and a built0in re-slotting cadence to keep performance on track post-launch.

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Challenge

  • The client was preparing a rapid DC transition and needed an executable forward-pick and storage plan.
  • Key gaps included inconsistent SKU attributes (dimensions/UOM/handling) and uncertainty around racking, shelving, and material-handling needs to support picking flow.
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Approach

  • Validated facility layout and location dimensions, then cleaned and standardized SKU attributes and order history to build a 3D slotting model.
  • Ran greenfield and constrained optimization scenarios to produce a location-level slotting plan and identify required rack/shelving and MHE adjustments.
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Results

  • Forward-pick covers 87% of line activity.
  • Slotted 80% of the active inventory cube.
  • Storage media designed for execution.