"We are running out of space."

"We can't fulfill orders fast enough."

"We're not ready to take on additional volume."

If your warehouse or distribution center (DC) is experiencing these constraints, you're not alone. Knowing how to effectively utilize your existing space (or open a new one) to satisfy business requirements is key in today's fiercely competitive market. 

LeanCor's warehouse design and deployment solutions provide a current state assessment and future state vision of your warehouse/DC that delivers best-in-class results in material flow, processes, technology, and management systems.


Free Webinar with WERC: Designing a New DC Based on Lean Principles to Meet Aggressive Growth Projections

In 2018, BG Products, Inc. recognized that the existing operation could not accommodate aggressive future growth projections. In this free webinar, hear how BG and LeanCor solved these challenges by building a new DC based on lean design principles

Watch Now

Download Presentation Slides

More Warehousing and Distribution Resources

10 Tips to Improve Your Warehouse Receiving Process

With some easy-to-implement solutions, your facility can start to realize major gains in worker productivity, error reduction, receiving volume, and more.

Download E-Book


Is your warehouse "firefighting" or "fireproofing?"

In a warehouse design engagement, we assess your current state while incorporating your vision, strategy, and operational requirements. You receive a visual, detailed, best-in-class layout and material flow design that will prepare your warehouse(s) for whatever comes your way.

This includes:

  • Warehouse/DC vision and operating principles
  • Data collection plan
  • Base case design and targets (baseline for improvement)
  • Alternative-scenario designs, capital expense plans, and operational budgets
  • Recommended conceptual design (future state)
  • Material flow plan
  • Vendor and technology evaluations
  • Road map
  • Virtual warehouse training for teams


Our warehouse design methodology is grounded in a pragmatic balance between operational reality and best-in-class standards.

First, we define your strategy and operational principles. Next, we define the target condition - or "base case" - for current operations without substantial capital investments or infrastructure changes. Then, we compare the latest technological options, identifying the right usage of conventional, mechanized, and automated applications -- without bias. From there, we create capital expenditure plans and operational budgets that will minimize your investment while reducing operational costs. Finally, we define detailed design inputs for future provider RFPs and a step-by-step road map to guide your implementation. 




Warehouse Vision: Picture Your Future State

After the current state assessment and establishing baselines for improvement, we provide you with a road-map style vision with a detailed layout and material flow design. 

Upon agreement from all stakeholders, we'll help you manage the execution of this vision with LeanCor on-site resources or third party providers.


Measures of Success

From the project kickoff to the final report-out presentation, LeanCor is relentlessly focused on identifying and delivering results in the most important aspects of an operation:

Warehouse Design Case Studies

Success stories with our clients

Lean Warehouse Assessment

Warehouse Assessment (Pharma)

An international pharmaceutical company had several consulting engagements where only limited results were realized. The client sought a more thorough assessment that could deliver immediate, short-term, and long-term tangible results.

Read the story (PDF)

DC Design Case Study - BG Products

Distribution Center Design (Automotive)

With aggressive future growth projections, BG Products' existing 50,000-square-foot distribution center (DC) couldn’t accommodate efficient material flow to support the impending volume. 

Read the story in Inside Logistics

Read more from BG Products

DC Consolidation Case Study (1)-1

Warehouse Consolidation / Deployment (Automotive) 

An automotive supplier’s warehouse space and on-hand materials were growing exponentially as it received, processed, and stored material for potential future use.

Read the story (PDF)


Solution Packages - Levels of Engagement

We've learned that every client is at a different place on the maturity scale with its warehousing. Some are lacking an inventory management strategy. Others have inefficient flow. Wherever your organization may be, our strategic engagement model allows us to customize an approach to fit your unique needs.


  • 5-10 future state scenarios
  • Technology RFI and analysis
  • Cash flow road map

12-14 Weeks

LeanCor Led (Automated + Mechanized + Conventional)


  • Base case improvements
  • 3PL outsourcing analysis
  • 3-5 scenario ROI analyses
  • CAD drawing
  • Road map

8-10 Weeks

LeanCor Led (Conventional)


  • Facility design
  • Implementation templates
  • Capital expense vs. operational cost analysis
  • Periodic coaching calls
  • On-site tollgate reviews


8-10 Weeks

LeanCor Coached (Conventional)

Why We're Different...


We gather and understand voice of customer to maintain strategic alignment and deliver strategic opportunities that will drive results.



Our recommendations come from experienced supply chain operators within our integrated divisions designed to teach, consult, and execute the lean supply chain. 


Rooted in lean principles and advanced supply chain problem solving, our methodology has been validated to deliver recommendations in excess of 10 times the typical investment.

Quick Wins

We execute immediate improvement strategies to create short-term stability.


"No Great Unveilings"

We practice disciplined, collaborative, and formal tollgate management to ensure client ownership of report-outs.



From project kick-off to final delivery of assessment findings, LeanCor is relentlessly focused on identifying and delivering results.

Bottom line, this change is because your team is hardworking, honest, personable, practical, willing to teach, willing to listen, and truly has our company's best interest at heart!