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Warehouse Optimisation
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Faster, smarter, cost-efficient warehouses.

Spanzia re-engineers how your warehouse uses its space and runs its operations, layout, storage, slotting, workflows and cost-effective automation, to lift throughput and cut cost per unit.

Get in Touch See the Problem

Running below potential, in space and process.

The six space and process inefficiencies we see most often. Tap to explore.

Slow picking, low throughput
Slow picking, low throughputPick rates below target and orders-per-shift that won't grow even as headcount rises, a process problem you can't hire your way out of.
Wasted space, poor storage fit
Wasted space, poor storage fitUnder-used vertical height, aisles sized for equipment you no longer run, and storage types mismatched to your SKU profile.
Dock bottlenecks, aisle congestion
Dock bottlenecks, aisle congestionPicking, replenishment and inbound traffic competing for the same aisles, with trucks and staging backing up at the docks.
Broken put-away process
Broken put-away processStock landing but not moving cleanly to its location, slow, unstructured put-away that creates staging backlogs and stock that can't be found.
People safety, cargo security
People safety, cargo securityCongested traffic, poor segregation and blind spots that put people at risk and leave high-value cargo exposed.
Manual, unmeasured operations
Manual, unmeasured operationsPaper and spreadsheet-driven processes with no baseline, so no one really knows where the time, cost and errors are going.
Get in Touch See how we work

Six stages. Observe to optimise.

Step through each stage to see what it does and what's in scope.

1
Observe
3
Analyse
4
Redesign
5
Implement
6
Optimise
What we do
Observe

Every optimisation starts with reality. Spanzia runs structured on-site observation of live operations and current space use across all shifts, receiving, put-away, picking, packing and dispatch.

Why it matters
  • We see what actually happens on the floor, not what the SOPs say.
  • Space and process are assessed together, as one system.
In Scope
On-site observationLayout & space auditShift coverageCurrent-state mapping
What we do
Measure

We quantify current performance and space, pick rates, travel distances, dock cycle times, error rates, labour utilisation and space utilisation, from your systems and a time-and-motion study.

Why it matters
  • What cannot be measured cannot be managed, so we build a hard baseline first.
  • Every later gain is proven against these numbers.
In Scope
Pick & throughput ratesSpace utilisationTravel & cycle timesError & labour data
What we do
Analyse

Root-cause analysis across every measured inefficiency, separating process problems from layout, storage and slotting problems, and systemic issues from one-offs.

Why it matters
  • We fix causes, not symptoms.
  • You learn whether it's a method, a layout or a slotting problem.
In Scope
Root-cause analysisProcess vs. space splitSlotting & velocityBottleneck mapping
What we do
Redesign

We redesign layout, storage, slotting and end-to-end workflows together, and introduce cost-effective automation only where it earns its return.

Why it matters
  • Never automate a redundant process, we fix the process first, then automate.
  • Faster, smarter and cost-efficient by design.
In Scope
Layout & storage redesignSlotting strategyWorkflow redesignCost-effective automation
What we do
Implement

Structured, phased rollout of space and process changes to minimise disruption to live operations, with SOP documentation, staff briefing and training.

Why it matters
  • Gains delivered without stopping the operation.
  • Teams are brought along, not bypassed, so improvements stick.
In Scope
Phased rolloutSOP documentationStaff trainingChange management
What we do
Optimise

Post-implementation review against the baseline, confirming improvements, capturing remaining opportunities, and establishing ongoing KPI monitoring so performance is sustained.

Why it matters
  • Improvements confirmed against the numbers, not assumed.
  • Performance is sustained and built on, not a one-off.
In Scope
Baseline comparisonKPI dashboardsContinuous improvementPerformance review
Get in Touch Read the FAQs

Warehouse optimisation questions, answered.

What is warehouse optimisation?
Warehouse optimisation is the redesign of how a facility uses its space and runs its operations, layout, storage, slotting, and end-to-end workflows, to make it faster, smarter and more cost-efficient. Spanzia treats space and process as one system, and introduces cost-effective automation only where the operation genuinely justifies it.
What's the difference between space optimisation and process re-engineering?
Space optimisation focuses on the building, layout, racking, storage density and vertical utilisation. Process re-engineering focuses on the work, receiving, put-away, picking, packing and dispatch. Because the two are inseparable, Spanzia delivers them together as a single optimisation engagement rather than in isolation.
How do you improve picking and packing efficiency?
Picking and packing are usually the highest labour-cost activities in a warehouse. Spanzia assesses pick methodology, path logic, batch and wave structure, slotting and pack-station design, then redesigns the end-to-end fulfilment process to raise output per labour hour without adding people or space.
Do you recommend warehouse automation?
Only where it pays. Our principle is simple: never automate a redundant process. We fix and streamline the process first, then assess cost-effective automation against your throughput and labour-cost profile, so you invest in automation that earns its return rather than automating waste.
Can you increase capacity without relocating?
Often, yes. A large share of capacity is recovered by better use of vertical height, right-sized racking, ABC velocity slotting, aisle reconfiguration and removal of non-productive floor use, before any thought of a larger building. Spanzia quantifies the achievable gain from your existing footprint first.
How do you maximise storage space and vertical utilisation?
Through vertical utilisation analysis, racking-type evaluation (selective, drive-in, push-back, mobile, mezzanine), ABC velocity slotting, aisle-width review where equipment permits, and elimination of non-productive floor usage, all matched to your SKU and velocity profile.
Do you assess existing operations before recommending changes?
Always. Every engagement starts with an Observe and Measure phase, structured observation of live operations and a hard baseline of pick rates, travel, cycle times, error rates and space utilisation. What cannot be measured cannot be managed, so recommendations are grounded in your data, not generic benchmarks.
Is warehouse optimisation relevant for smaller warehouses?
Yes, often more so. Space optimisation frequently delivers proportionally greater returns in smaller facilities where every square metre counts, and process gains scale with throughput. Spanzia scopes engagements to the size and complexity of your operation.
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