Distribution Center Design & Implementation

OPSdesign^® completed a distribution center design and implementation project for a leading performance sock and apparel brand in the Southeast serving Direct-to-Consumer, Business-to-Business, specialty retail, running store, national account, distributor, and e-commerce channels. The company was experiencing rapid business growth and needed a long-term distribution strategy that could support higher order volume, expanded inventory, and increased SKU complexity without unnecessary labor growth or capital investment.

OPSdesign evaluated the company’s existing distribution operation and identified several constraints that would limit future scalability. Sales and inventory were projected to nearly double within five years, active SKU count was expected to increase by more than 60%, and warehouse storage capacity was already being exceeded during peak periods. Current facility utilization was projected to reach more than 240% of available capacity within the planning horizon.

The project focused on creating a facility design and implementation plan that improved storage capacity, picking efficiency, inbound staging, replenishment, quality control, returns processing, and system-supported warehouse workflows. The resulting design balanced near-term operational needs with long-term growth requirements, helping the company scale its distribution operation without relying on excessive overtime or manual workarounds.

Details of Project

• Designed and implemented a new facility layout with combined B2B and DTC picking zones.
• Created a dedicated catalog release area to support product launch activity.
• Expanded storage infrastructure to better support projected inventory growth and peak season volume.
• Recommended WMS enhancements, including enhanced batch picking, slotting, and directed putaway.
• Developed RF-supported replenishment zones to improve inventory flow and reduce manual processes.
• Improved inbound staging and created dedicated areas for quality control and returns processing.

Deliverables/Results

The completed design and implementation supported a more scalable distribution operation with improved storage utilization, more structured picking and replenishment processes, and dedicated operational areas for inbound, quality control, returns, and catalog release activity. Following implementation, measured shipping output increased by 49%, allowing peak season demand to be handled without the use of overtime.