OPSdesign® completed a warehouse reconfiguration and conveyor integration project for a worldwide eyewear distributor serving the premium fashion sector. The client needed to redesign storage and key processing areas, connect multiple warehouse functions through an integrated conveyor network, and establish standardized operating procedures to support more efficient daily operations.
OPSdesign developed a revised warehouse layout covering storage and all major processing areas, including receiving, picking, value-added services, packing, shipping, and returns. The team also prepared a phased implementation plan that outlined the relocation and modification timeline for each processing area so the client could sequence the changes in a practical, controlled way.
A key part of the engagement was the integration of a conveyor system that connected receiving, storage, two floors of picking, packing and manifesting, and carrier sortation.
OPSdesign incorporated pick-area induction points so picked cartons could move directly to packing and manifesting, reducing travel and eliminating the need for separate cart staging space.
To support the physical changes, OPSdesign helped develop a comprehensive SOP set for core warehouse processes, including receiving, put-away, order waving, cart picking, single-unit picking, cycle counting, replenishment, and outbound operations.
Details of The Warehouse Reconfiguration & Conveyor Integration
24%
Estimated labor reduction
48K-60K
Daily order capacity designed
0
Cart staging space required
The Challenge
The client needed to redesign storage and key processing areas, connect multiple warehouse functions through an integrated conveyor network, and establish standardized operating procedures to support more efficient daily operations across two floors of picking.
What We Did
- Redesigned storage, receiving, picking, VAS, packing, shipping and returns
- Phased implementation plan for each area relocation
- Conveyor connecting receiving, storage, two pick floors, packing, manifesting and carrier sortation
- Pick-area induction points sending cartons straight to packing
- Comprehensive SOP set from receiving through outbound
Results
- Reduced walking between pick floors and packing
- Structured relocation and modification roadmap
- Clearer operating model through a full SOP framework
Deliverables/Results
The project delivered an integrated warehouse concept that connected layout improvements, conveyance, implementation planning, and process standardization. The redesigned operation reduced walking distance from the two pick floors to the packing area, removed the need for cart staging space, and created a clearer operating model across inbound, storage, picking, replenishment, and outbound functions.
- Estimated 24% labor reduction through the warehouse reconfiguration.
- Daily throughput capacity designed to process 48,000 to 60,000 orders.
- Reduced non-value-added walking between picking and packing areas.
- Eliminated cart staging space by conveying picked cartons directly from pick-area induction points.
- Provided a structured relocation and modification roadmap for implementation.
- Improved process clarity through a comprehensive SOP framework.
Maximizing warehouse throughput requires aligning physical space, material handling equipment, and daily standard operating procedures. Whether you are retooling existing floor space, reducing travel distances across multi-level pick zones, or connecting critical processing areas with powered conveyance, our engineering team delivers practical strategies that drive measurable labor savings.
Contact OPSdesign today to discuss your next warehouse reconfiguration & conveyor integration project and learn how our phased implementation planning can transform your operations.
