Warehouse Consulting:   
Warehouse Logistics & Optimisation

We help businesses identify warehouse inefficiencies, improve layouts and increase operational performance through practical, data-led consultancy.

Re-engineering Existing Warehouses To Improve Performance

When growing sales demand more from your facilities, LPC International is here to help. We specialise in re-engineering existing facilities to increase storage capacity, expand product range capabilities, and improve productivity. By mapping current processes, implementing new workflows, and integrating advanced warehouse management systems, we ensure your operations are streamlined and costs are reduced.

In many cases, extending the life of an existing facility can provide the time needed to plan for a new one. With the right equipment, processes, and material flow improvements, moving to a new site may not even be necessary.

LPC International combines expertise in facility optimisation with proven strategies to help businesses adapt and grow efficiently, ensuring you stay ahead of the demands on your supply chain.

Consultancy Support and Design

A smaller operation will still encounter many of the issues and problems of a larger operation. Alternatively, a company may want to improve the knowledge and capability of their operational team.

LPC can provide consultancy support to improve the warehouse layout and operation by working on site with the warehouse manager and senior team. A senior consultant will audit the operation and facility advising on the options for everything logistically or operationally related and work with you to produce the solution to your problems, and opportunities!

View Our Case Studies

What Does It Mean To Re-Engineer A Warehouse And What Does It Entail?

Re-engineering is the process of changing your current operation and set up to meet your current or future needs and business objectives. It usually starts with a need being identified –e.g. to increase storage capacity, improve productivity, reduce costs. However, the scope and ramifications will vary.

Re-engineering a facility is almost always cheaper than moving, provided what you require can be done. Don’t forget that physical changes are only one element, operational processes and IT systems are others, as are elements that are impacted or are affected by the warehouse operation such as purchasing and sales.

The warehouse layout may be a legacy that is experiencing diminishing efficiencies or simply that it is required to achieve greater capacity and or throughput. Warehouse enhancement might simply be a project to reduce costs and raise service levels. Whatever the requirements we can advise on a host of initiatives for the short term to the longer-term planning to improve warehouse efficiency.

 

LPC-Guide (2)

In a downturn, logistics can either drain your business or drive your advantage.

This practical guide shows SMEs how to stay resilient, protect cash, and keep service levels strong.

Learn how to:

  • Identify and reduce supply-chain risk before it disrupts your operations
  • Protect cash flow and control costs with smarter contracts and lean logistics
  • Improve agility and lead times through diversification and better inventory strategy

Complete the form provided to receive your copy.

If you think you have the need to Re-Engineer your facility you will need to ask yourself the following questions:

Operational Layout

– Does the warehouse flow without constraints?
– Are materials straightforward and optimised?

ABC Classification

– Are your SKU’s correctly allocated?
– Are your product flows minimalised?
– Are you experiencing congestion areas?

Business Changes

– Do you need to accommodate new customers?
– Is there a requirement for increased picking?
– Introduce a packing operation to support e-commerce?

Storage Requirements

– Do you have the right storage media for the application?
– Is the storage layout optimised?
– Is it flexible and cater for growth?
– Are you getting efficient utilisation?

Re-Engineering

– Can physical changes be made to the facility?
– Can the facility be extended?
– What impact will growth have on operational life left in the warehouse?
– Is there opportunity to physically reformat the warehouse?

Storage Equipment/Media

– Is the storage media still fit for purpose?
– Does the type and layout of media meet future requirements?
– Is the space and height used – is there efficient use of the cube?
– Are you achieving industry standard KPI’s?

Audit

– Is the warehouse meeting KPI’s?
– Benchmark against industry standards
– Are you meeting orders?
– Are you being forced to double handle or search for items
– Do you have the right resource allocation?

Book A Meeting

LPC International helps you adapt by re-engineering facilities to boost storage, optimise workflows, and reduce costs. We can extend the life of existing sites or plan for future expansion - often eliminating the need to relocate.

Our Other Warehousing Services

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Book an initial, no-obligation meeting with one of our consultants and benefit from over 40 years of experience

Case Studies

Explore some of our most successful logistics and warehousing projects.

View All Case Studies

Common Warehouse Problems We Help Solve

Running out of warehouse space

We optimise layouts, storage systems, and workflows to maximise your existing capacity before recommending expansion.

Low picking productivity

We streamline picking processes, improve slotting, and introduce the right technology to increase accuracy and throughput. High labour costs – We identify opportunities to improve efficiency through better processes, automation, and workforce optimisation.

Inefficient warehouse layout

We redesign warehouse layouts to minimise travel distances, improve material flow, and support future business growth.

Difficulty coping with business growth

We design scalable warehouse solutions that enable your operation to handle increasing demand without compromising efficiency or customer service.

Industry Insights

HOW BEST TO CONSIDER IMPLEMENTING AUTOMATION?
Modern warehouse facility showcasing advanced warehouse automation systems and logistics operations.

HOW BEST TO CONSIDER IMPLEMENTING AUTOMATION?

25 Jun 2026, 11:00:02 2 min read
WHEN SHOULD SME’s CONSIDER AUTOMATION?
Warehouse team working with modern warehouse automation systems to improve operational efficiency.

WHEN SHOULD SME’s CONSIDER AUTOMATION?

18 Jun 2026, 11:00:03 2 min read
REPLENISHMENT BEST PRACTICES
Warehouse staff managing inventory and stock replenishment processes in a modern distribution centre.

REPLENISHMENT BEST PRACTICES

11 Jun 2026, 11:00:02 1 min read

FAQ

When should we re-engineer an existing warehouse?

You should consider re-engineering your warehouse when operational costs increase, capacity becomes constrained, productivity declines, or business requirements change.

Can warehouse improvements be made without moving facility?

Yes, many warehouse improvements can be achieved within your existing facility through layout optimisation, process improvements, and appropriate technology.

How do you identify warehouse inefficiencies?

We analyse your warehouse layout, processes, data, resource utilisation, and material flows to identify opportunities for improvement.

Do you help with implementation as well as recommendations?

Yes, we provide end-to-end support from developing recommendations through to supplier selection, project management, implementation, and commissioning.

How long does a warehouse review usually take?

A warehouse review depends on the size, complexity, and scope of your operation. Am informal discussion with one of our expects will quickly define the time period.

Book a Free Logistics Health Check

Your chance to get the benefit of 40 years of experience in offering practical solutions to warehousing & logistics problems, at no cost.