Warehouse Planning

Efficient Warehouse Planning
for Maximum Success

Accurate warehouse planning is crucial, as up to 25% of all logistics costs are attributed to the setup and operation of a warehouse. At EPG Consulting, we understand this dynamic and help you uncover and leverage untapped potential. Our experts assist you in the proactive and precise planning of your logistics. Whether it’s designing a new warehouse or optimizing existing warehouse structures, we are here to support you throughout all planning phases.

Our approach includes state-of-the-art warehouse planning software that allows us to identify bottlenecks early and avoid errors during the planning phase. Using this solution, we create an immersive 3D visualization of your warehouse, making allowing you to virutally explore your setup before it physically exists. Utilizing real material flow data in our virtual reality solution significantly enhances planning security.

Marcel Wilhelms, General Manager

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A Warehouse Plan That Benefits You.

1. CONCEPTUALIZATION

With our manufacturer-independent consulting, we focus on customized warehouse planning concepts tailored precisely to your company’s needs. Our goal is to develop a warehouse that not only meets current requirements but also allows you to flexibly respond to future developments. We leverage innovative warehouse management systems, material flow controls, and automation technologies such as conveyor systems and robotics to optimize your warehouse processes and enhance efficiency.

2. PLANNING

During the warehouse planning process, the experts at EPG Consulting guide you through all planning phases, collaborating with you to set strategic goals and optimize your processes for efficiency. Our comprehensive consulting services also include negotiations with external service providers and suppliers, ensuring that your logistics remain cost-effective and competitive.

3. SIMULATION

Our material flow simulation allows companies to virtually represent and analyze their warehouse structures. Through precise modeling of processes and layouts, you gain detailed insights into the flow of goods and materials within your warehouse. These simulations help identify bottlenecks, determine optimal storage placements, and suggest process improvements. By utilizing material flow simulations, we minimize risks and costs associated with redesigning or restructuring your warehouse infrastructure. The accurate predictions and analyses empower you to make informed decisions and continuously enhance your warehouse environment.

4. PROCUREMENT AND AWARDING

Successful warehouse planning requires precise procurement processes and the selection of the right partners. Our extensive experience in warehouse planning makes us your ideal partner in this regard. We understand the complexity of this process and are committed to providing you with tailored solutions. We place great importance on remaining neutral and independent throughout all phases of the procurement and awarding process. Our focus is on ensuring that your decisions are based on objective criteria and yield optimal results for your company.

5. PROJECT MANAGEMENT

The smooth operation of a warehouse requires more than just physical space and shelves. At EPG Consulting, we understand that project realization in warehouse planning is a comprehensive process that demands precise planning, expertise from various fields, and effective management. Our multidisciplinary team of logistics experts, IT engineers, and project managers collaborates closely with you to develop a tailored strategy. This comprehensive approach includes setting goals, establishing precise timelines, and optimizing resource utilization.

1. CONCEPTUALIZATION

2. PLANNING

3. SIMULATION

4. PROCUREMENT AND AWARDING

5. PROJECT MANAGEMENT

FACTSHEET

Holistic View of Your Logistics and Development of a New Logistics Concept

The foundation for any successful logistics project is thorough planning. This is especially true during the concept phase, where the focus is on selecting a cost-effective and flexible solution.

Enhanced Decision-Making in Warehouse Planning through Virtual Reality

We integrate modern visualization, simulation, and emulation solutions into our warehouse planning process to actively involve clients in the planning of complex logistics projects. With our 3D visualization, adjustments to the warehouse layout can be implemented quickly, allowing you to experience your warehouse digitally before building begins. The Holodeck presents the results clearly, significantly improving planning security and ultimately enhancing cost-effectiveness.

Note: This is a 360-degree video. Use your mouse or the arrow keys on your keyboard during playback to change perspectives and explore the space.

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Frequently Asked Questions About Warehouse Planning

What does professional warehouse planning include?

Professional warehouse planning develops a warehouse concept that aligns processes, capacities, space, and technology with the company’s actual requirements. Factors such as SKU profiles, order structures, throughput, seasonal peaks, labor requirements, and growth assumptions are taken into account. The result is not merely a layout, but a robust basis for investment, tendering, and implementation. EPG CONSULTING supports the entire process from analysis and concept development through to procurement.

When should a company redesign or replan its warehouse?

Warehouse replanning makes sense when capacity is consistently constrained, performance limits have been reached, or significant changes occur in the product range, order structure, or service requirements. A planned site relocation, strong growth, increasing automation, or high process costs can also be triggers. However, not every challenge requires a new facility; optimization, expansion, or retrofit may be more economical alternatives.

Expand, restructure, or build a new warehouse: When is each option appropriate?

Expansion is a suitable option when the location and building structure remain viable in the long term and additional capacity can be created. Restructuring may be sufficient when processes, warehouse technology, or space utilization are the primary bottlenecks. A new facility becomes relevant when the existing conditions can no longer support future requirements. In addition to required performance, factors such as available land, building condition, investment requirements, and potential disruption to ongoing operations must also be considered. EPG CONSULTING compares these alternatives using specific performance, space, and investment scenarios.

How is the right warehouse technology selected?

The right warehouse technology should not be selected based on an individual product or system, but on the performance requirements of the warehouse operation as a whole. Key factors include throughput, SKU and load-carrier profiles, order structures, peak loads, available space, labor requirements, and expected growth. Requirements for availability, flexibility, and investment protection must also be considered. Only then can manual, semi-automated, and automated solutions be compared effectively.

Feel free to try our free warehouse technology comparison.

How much does professional warehouse planning cost, and what determines the cost?

Costs depend primarily on the project scope, data availability, the number of alternatives to be analyzed, required simulations, and the level of support needed through tendering or implementation. An initial analysis requires significantly less effort than complete planning that includes material flow simulation, 3D visualization, and procurement support. The level of planning detail should always be proportionate to the scale and significance of the investment decision.

How can planning errors be avoided before implementation?

Planning errors can be reduced through reliable data, realistic load assumptions, and the comparison of multiple solution scenarios. Common risks include overlooked peak loads, overly optimistic growth assumptions, poorly defined interfaces between project disciplines, or layouts that offer insufficient operational flexibility. Material flow simulations and 3D visualizations can make processes, bottlenecks, and risks visible before investments are implemented.