PROJECTS
New Warehouse Installation With High Density Storage Solution
Growth is a good problem to have — until your operation is scattered across more locations than it should be.
When demand climbs on every channel at once, the fix usually isn't more shelving; it's pulling everything into one space and rethinking how product moves through it. Here's how we helped a fast-growing eyewear brand bring it all under one roof.
THE challenge
Our client — a returning customer and a growing Canadian eyewear brand — was outgrowing its setup.
Operations were spread across three separate locations, and demand was climbing on two fronts at once: new stores opening across Canada, and online sales growing month over month. With a deep catalogue of frames, each model carrying its own SKUs, they needed one building to do two very different jobs — pick and ship direct-to-consumer orders, and replenish their retail stores — without the system buckling under the growth.
THE outcome
We started where we always do — a conversation — then designed a single, denser operation around how their orders actually flow.
A batch-picking system built on flow racks let pickers run efficient routes instead of criss-crossing the floor, densifying storage and speeding up the pick. From there, a put wall sorted picked items by order, so packers could pack accurately at ergonomic packing stations built to stay comfortable through high volume. The result: one consolidated building doing the work of three — tighter storage, fewer shipping errors, and more orders out the door every day.
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