International supplier of specialized equipment

Tasks

Development of an optimal layout for a new warehouse facility on the client’s site, taking into account the existing infrastructure, transportation flows, and operational requirements.

The project was initiated due to capacity constraints at the main warehouse and the inefficient use of outdoor storage areas. The objective was to create a modern logistics solution capable of increasing productivity, reducing operating costs, and providing a scalable foundation for future growth.

What was done

The project began with an assessment of the available site and an evaluation of potential construction locations. The NOYTECH team conducted a technical survey of the area and proposed the optimal building placement while considering existing constraints.

As a result, a warehouse building with external dimensions of 102.7 × 42.7 meters was designed. This configuration maximized usable space and enabled seamless integration into the existing infrastructure without disrupting ongoing operations.

Particular attention was given to the organization of material and transportation flows. NOYTECH specialists developed a traffic management scheme that separated vehicle movements based on shipment types and cargo categories.

A detailed goods flow map was created, incorporating maneuvering and staging areas as well as optimized dock interfaces. This approach minimized traffic intersections, enhanced workplace safety, improved occupational health conditions, and increased the overall throughput of the site.

During the warehouse layout design phase, three implementation scenarios were developed:

• A warehouse with a capacity of 3,876 pallet positions, operated using standard material handling equipment.
• A warehouse with a capacity of 7,104 pallet positions, utilizing high-bay handling equipment.
• A 4,227 sq. m distribution center designed for unloading, storage, and outbound operations using multiple types of handling equipment.

Special consideration was given to ceiling height options (6, 8, and 12 meters) and the efficient arrangement of racking systems while maintaining safe working areas.

In addition, a comprehensive site master plan was developed, including traffic circulation schemes and options for repurposing auxiliary buildings. This holistic approach ensured the long-term development of the logistics infrastructure rather than focusing solely on the construction of a new warehouse.

Result

Project

• A master plan for a warehouse facility with external dimensions of 102.7 × 42.7 meters.
• Building layout designs, transportation flow schemes, and plans for optimizing supporting operational areas.
• Three warehouse implementation concepts with a total building footprint of 4,385 sq. m.

Expected Business Impact

• Reduction of loading and unloading time to 1 hour per vehicle, saving up to 30 operational hours per day in inbound and outbound handling.
• Improvement in order picking accuracy from 90% to 99%.
• Reduction in warehouse losses by 2%.
• Decrease in reverse logistics costs by 15%.
• Increase in warehouse throughput by 50% while maintaining standard operating hours.