Distribution and fulfillment operations are under increasing pressure: more SKUs, faster order cycles, higher accuracy expectations, and labor markets that make manual-intensive operations structurally expensive. The facilities and systems that worked five years ago often can't meet today's demands without redesign.
FloStor designs and integrates warehouse and distribution systems that are optimized for your products, your order profiles, and your growth trajectory. From facility layout and slotting strategy through storage system selection, automation, and operational consulting — we build distribution operations that perform at the metrics your business needs.
Facilities laid out for a previous product mix or lower volume often have SKU slotting that doesn't match current velocity profiles — pickers walk miles per shift to reach fast-moving items that should be in primary pick zones, directly inflating labor cost per unit shipped.
Receiving and shipping dock layouts that worked at lower volume become chokepoints as throughput grows — trailers queue, sort staging overflows, and the dock becomes the constraint on the entire facility regardless of how well the storage and pick areas perform.
Distribution operations designed for average throughput often can't absorb peak season volume spikes — labor is added but physical constraints on space, dock doors, and system capacity create throughput ceilings that temporary staffing cannot overcome.
Operations that evolved from single-channel (B2B pallets) to omnichannel (B2B mixed case + DTC parcel + store replenishment) often run parallel manual systems for each channel — multiplying labor, reducing accuracy, and making operational management unnecessarily complex.
Distribution performance is determined by the interaction of four variables: space utilization (are you storing product in the right locations?), flow path design (are workers moving efficiently?), system integration (is information flowing between WMS, equipment, and workforce?), and throughput capacity (can the physical system handle your peak volume?).
FloStor's approach begins with a current-state assessment that measures your baseline on each of these variables, then identifies the highest-leverage improvement opportunities. Sometimes the highest-ROI action is a slotting change that costs almost nothing. Sometimes it's a facility expansion and storage system redesign. We help you distinguish between the two before any capital is committed.
For major redesigns, we use simulation modeling to validate layouts and system designs against your actual order profiles and throughput requirements. Equipment is selected to match your products, not the other way around — and integration architectures ensure your WMS, automation, and operations teams are working from the same data.
Space utilization analysis, dock layout design, flow path optimization, and SKU slotting strategy that maximizes throughput and minimizes labor per unit shipped.
Selection, design, and integration of pallet racking, mezzanines, AS/RS, and other storage systems that maximize density and accessibility for your specific SKU profile.
Conveyor systems, sortation equipment, and picking technology that break through throughput ceilings and support scalable growth without proportional labor increases.
Integrated systems that support simultaneous B2B, DTC, and store replenishment fulfillment from a single facility without duplicate infrastructure or siloed operations.
Turn-key project management for facility redesigns, automation deployments, and system integrations — including schedule management, subcontractor coordination, and go-live support.
Operational analysis, slotting studies, labor productivity assessments, and process improvement consulting that deliver measurable results without major capital investment.
We assess your existing facility, throughput metrics, order profiles, labor costs, and operational challenges to establish a baseline and identify priority improvement opportunities.
Based on the assessment, we develop a prioritized improvement strategy — distinguishing between low-cost process improvements and capital-intensive redesigns based on ROI.
Our engineers develop facility layouts, storage system specifications, automation designs, and integration architectures — all validated against your throughput requirements.
Layouts and system designs are modeled in discrete-event simulation to confirm throughput capacity, identify remaining bottlenecks, and validate ROI projections.
We manage the full implementation process — equipment procurement, installation, integration, and training — with a phased approach to protect operational continuity.
Post-implementation performance monitoring, system tuning, and operational consulting ensure your redesigned distribution operation delivers its designed performance metrics.
Increase in throughput after facility redesign and flow optimization
Reduction in labor cost per unit shipped after slotting and system redesign
Improvement in space utilization from storage system redesign
Order accuracy achieved with integrated automation and scan-verify systems
* Based on FloStor client implementations across distribution and fulfillment environments
Our distribution specialists will assess your current operation and identify the highest-ROI improvements — whether that's a slotting change or a complete facility redesign.
Request a Distribution Assessment
Contact our distribution specialists to start the conversation about transforming your warehouse performance.
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