Midwest's Most Experienced Integrator
Warehouse Design &
Consulting Services
From the first site visit to the final rack installation, MWS delivers turnkey warehouse design and consulting grounded in 50+ years of real-world Midwest experience — not generic software outputs. We optimize your operation before we recommend a single dollar of capital investment.
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515-635-1555
12
States in Our
Service Territory
1,200+
Projects Successfully Completed
4.8M+
SKUs Analyzed & Slotted
40+
Year Engineering
Partnership
99%
Customer Satisfaction Rate
Home / Services / Warehouse Design & Consulting Services
Warehouse Design & Layout
Consulting for the Midwest
A well-planned warehouse helps your team move efficiently, use available space, and prepare for growth. Warehouse design and consulting brings together a review of your layout, daily operations, inventory, and business goals to identify bottlenecks and develop a practical improvement plan. This can include analyzing product movement, storage locations, picking activity, and receiving and shipping areas, then creating CAD layouts and equipment recommendations that balance productivity, safety, capacity, and cost.
Based in Goldfield, Iowa, Midwest Warehouse Solutions provides warehouse design, equipment integration, and installation services across the Midwest. We start by understanding how your operation works and where improvements can make the greatest difference. Our approach is to optimize before recommending automation, using operational data and input from your team to guide layout and equipment decisions. From reconfiguring an existing space to planning a new facility, we help turn those recommendations into a coordinated plan built around your workflow, budget, and future needs.
You need a warehouse
design consultant when:
- Your facility is approaching 85%+ storage capacity and operational compromises are multiplying
- Pick labor cost per order has grown 15%+ without a corresponding increase in order volume
- SKU count has grown 20%+ without a formal slotting review
- You are signing a new lease, expanding, or evaluating a new facility
- You are considering automation — conveyors, AS/RS, AMRs, VLMs — and want to optimize the baseline first
- Order accuracy or throughput per labor hour is deteriorating despite hiring efforts
- You've grown through acquisition and need to consolidate or right-size your warehouse network
- A key account is demanding faster turnaround than your current layout can support
The right time for a warehouse consulting engagement is almost always earlier than most operations managers realize. By the time the pain is obvious, the design options are more limited and more expensive.
OUR WAREHOUSE DESIGN & CONSULTING SERVICES
A Complete Suite of Warehouse
Design & Consulting Services
MWS delivers end-to-end warehouse design and consulting — from initial data analysis through final installation and post-go-live optimization. Whether you need a targeted slotting analysis for an existing facility or a comprehensive greenfield distribution center design, we have the methodology, tools, and execution depth to deliver it. Call 515-635-1555 to discuss which service fits your current challenge.
Warehouse
Layout Design
The physical foundation of every efficient operation. We produce 2D and 3D CAD drawings of your optimized facility — covering rack placement, aisle configuration, receiving and shipping zones, staging areas, pick modules, and dock design, all engineered to OSHA standards and local fire code.
- 2D floor plans + 3D renderings for major projects
- Equipment-specific aisle width validation
- OSHA 1910.176 and NFPA 13 compliance built in
Slotting Analysis
& Optimization
Poor slotting accounts for 20–35% of excess picker travel in a typical warehouse. We analyze 90+ days of your order history to classify every SKU by velocity and build a slotting plan that puts your A-items in the ergonomic golden zone — nearest the primary pick path, at waist-to-shoulder height.
- ABC/Pareto velocity classification of full SKU catalog
- Golden zone placement for top-velocity items
- Available as standalone service or integrated with layout design
Throughput Analysis
Where exactly does your capacity break — and what does fixing it deliver? We model your real-world throughput ceiling using your order data, staffing model, equipment capabilities, and layout, identify the specific bottlenecks, and quantify the gain available from each proposed change.
- Peak-day and average-day throughput modeling
- Bottleneck identification: dock, pick, pack, sort
- Quantified ROI projection for each design alternative
Warehouse Capacity Planning
Running out of space is a predictable crisis — and a preventable one. We build 3- to 5-year capacity models using your cube utilization data, SKU growth trajectory, and seasonal demand patterns to identify the storage, layout, and footprint changes needed under multiple growth scenarios.
- Cube utilization baseline and 85%+ target roadmap
- Multi-scenario growth modeling (conservative / base / aggressive)
- Rack, mezzanine, and footprint expansion recommendations
AS/IS–TO-BE Modeling
Before you can design the right future, you have to honestly document the present. Our AS/IS assessment captures every dimension of your current operation — layouts, product flows, KPIs, equipment, staffing — and the TO-BE design closes every identified gap with data-justified changes.
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Forensic current-state audit: every bay, aisle, and KPI documented
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Gap analysis against industry benchmarks for your vertical
-
TO-BE design grounded in AS/IS findings, not assumptions
Automation Feasibility Assessment
Automation is not the right answer for every operation — and rushing to automate a broken layout is the most expensive mistake in warehouse operations. We evaluate your facility against a structured readiness framework and model specific automation ROI against the baseline of an optimized manual layout. If optimization delivers 80% of the ROI at 20% of the capital, we'll tell you.
- Structured readiness framework: throughput, SKU count, order profile, capital
- ROI modeling: VLMs, AS/RS, conveyor, AMR, sortation
- Honest recommendation — not a technology sales pitch
Site Selection &
Expansion Planning
Choosing the wrong building is the most expensive warehouse design mistake of all. We evaluate potential facilities against your operational requirements: clear height, dock door count, truck court depth, column spacing, sprinkler system type, floor load capacity, and local labor market — before you sign a lease or break ground.
- Pre-lease facility assessment checklist
- Dock door count calculation from throughput data
- Design-build coordination with architect and GC for new construction
Lean / 5S / Ergonomics Integration
Every MWS warehouse design begins with a waste audit — mapping all eight Lean wastes in your current operation and eliminating them from the physical design before we touch a CAD file. We design pick faces and workstations to minimize awkward lifting, excessive reach, and repetitive strain. This is not a checkbox — it is a design discipline that reduces injuries, lowers workers' compensation costs, and improves retention.
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Eight-waste Lean audit embedded in every engagement
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Ergonomic pick face design: reach distance, lift height, repetition
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5S visual management: floor markings, defined zones, label standards
The MWS Process from
Discovery to Optimization
Our warehouse design and consulting engagements follow a structured 7-phase methodology refined across 1,200+ projects in 12 Midwest states. Every phase has defined deliverables — so you always know where the project stands and what comes next. We don't believe in open-ended consulting retainers; we believe in defined scope, clear milestones, and measurable outcomes.
01
Understand Your Operation
What We Do
We review your space, workflow, equipment, and goals with your team. This helps identify challenges, project requirements, and opportunities for improvement.
What You Get
A site assessment outlining your current layout, improvement opportunities, and information needed for the next steps.
1–3 days on-site
report within 5 business days
02
Develop the Layout
What We Do
We create a proposed layout around your storage needs, material flow, and available space. Your team’s feedback helps refine the design to fit your daily operations and future plans.
What You Get
SKU velocity profile and ABC classification report, throughput analysis report, KPI benchmarking summary, design opportunity areas ranked by ROI potential.
1–2 weeks
(data availability is the primary variable)
03
Finalize the Plan
What We Do
We confirm the layout, equipment selections, and installation needs with your team. You receive a clear project scope and quote to guide the next steps.
What You Get
2–3 CAD concept layouts (2D floor plans), throughput comparison across concepts, rough cap
2–3 weeks
04
Coordinate Installation & Support
What We Do
We coordinate equipment delivery and installation around your facility’s needs and schedule. Our team remains available to answer questions and help with ongoing equipment and service needs.
What You Get
Full 2D CAD layout set, 3D rendering for major projects, rack bay specification sheet, slotting plan with SKU-to-location assignments, engineering drawings for permitting, finalized equipment bill of materials.
3–5 weeks
DELIVERABLES YOU RECEIVE
What's Included in a
Warehouse Design Engagement
Every MWS warehouse design and consulting engagement is defined by what you receive — not the hours billed. The following deliverables represent the complete set for a full-scope engagement. Individual projects may scope to a subset based on need and budget.
2D CAD Floor Plans
Precision-drawn layouts showing rack systems, aisles, dock areas, staging zones, and all fixed infrastructure. AutoCAD-compatible format.
3D Facility Renderings
Photo-realistic or wireframe 3D models of your redesigned facility for stakeholder approval and operational visualization.
SKU Slotting Plan
Complete SKU-to-location assignment map based on ABC velocity analysis — golden zone assignments, pick path routing, and replenishment logic.
Equipment Specification Sheets
Detailed specs for every piece of material handling equipment: rack type, beam capacity, upright height, conveyor specs, VLM models, dock leveler specs.
ROI Model & Payback Analysis
Financial model projecting labor savings, throughput gains, cube utilization improvements, and error reduction — with calculated payback period and NPV.
Capital Expenditure Plan
Full project cost summary with phasing options, financing opportunities via Saulsbury Hill Financial, and a prioritization framework for staged investment.
RFP Packages
Competitive bid specification documents for all major equipment categories, enabling apples-to-apples vendor comparison.
Phased Implementation Schedule
Sequenced installation roadmap designed to maintain operational continuity throughout the reconfiguration process.
Training Plans
Operational training documentation covering new pick paths, slotting logic, equipment operation, and updated workflows.
Ready to Optimize Your
Warehouse Layout?
Talk to a warehouse design consultant who has been solving Midwest storage and distribution challenges since 1979. Your free consultation includes an initial assessment of your current layout, throughput challenges, and design options — with no obligation and no pressure.
Or call us at 515-635-1555
METHODOLOGIES & FRAMEWORKS
The Analytical Frameworks Behind Every MWS Warehouse Design
Our warehouse design consulting is grounded in proven, data-driven methodologies — the same frameworks used by the world's leading supply chain engineering firms, applied with 50+ years of Midwest-specific implementation experience.
ABC Slotting / Pareto Analysis
Is the foundation of every slotting plan we build. In most warehouse operations, 20% of SKUs account for 80% of picks. Our ABC analysis classifies your full SKU catalog into three velocity tiers using your actual order history. A-items occupy the ergonomic golden zone — waist-to-shoulder height (28" to 60" off the floor), closest to the primary pick path. Correcting ABC assignments alone typically reduces picker travel 15–25%.
Throughput Modeling
Quantifies your operation's output capacity under current conditions, identifies specific constraints — pick congestion, dock throughput, packing station bottlenecks — and projects the capacity available in the TO-BE design. For larger projects, we use discrete-event simulation to test multiple layout scenarios before any capital is committed.
Cube Utilization Analysis
Measures your current storage efficiency against total available cubic volume. Most warehouses use only 40–60% of available cubic storage. Our target is 85%+. Closing that gap typically requires adjusting beam heights, adding rack to underutilized areas, and filling vertical cube with mezzanines or multi-level pick modules.
Lean / 5S Integration
Begins with a waste audit: mapping the eight wastes of Lean in your current operation and eliminating them from the physical design. Facilities that implement Lean warehouse design principles typically reduce non-value-added labor by 10–30%.
Aisle Width Optimization
Is the single biggest lever for increasing storage density without building a new facility — but it is constrained by your equipment fleet. Conventional counterbalance forklifts require 10–13' aisles; reach trucks operate in 9–10' aisles; VNA guided forklifts can work in 5–6' aisles. We model storage density gain vs. equipment investment for each configuration.
| Methodology | What It Does | When Used |
|---|---|---|
| ABC Slotting / Pareto Analysis | Classifies SKUs by velocity; positions A-items in ergonomic golden zone | Every engagement; standalone slotting projects |
| Golden Zone Picking | Designs pick faces for fastest, safest retrieval of high-velocity SKUs | All layout and slotting engagements |
| Class-Based Storage | Organizes warehouse into velocity zones for simplified re-slotting | High-SKU-count, 3PL, and seasonal distribution |
| FIFO / LIFO Flow Design | Designs rack systems to enforce product rotation (pallet flow, carton flow, push-back) | Food, pharma, perishable, regulated products |
| Throughput Modeling | Quantifies throughput ceiling; identifies bottlenecks; projects TO-BE capacity | All mid-to-large engagements; automation feasibility |
| Discrete-Event Simulation | Tests layout performance before build-out using simulation software | Large DCs, automation projects, high-stakes greenfield |
| Lean / 5S Waste Audit | Eliminates eight Lean wastes from physical design; embeds 5S visual management | All engagements as a baseline discipline |
| Cube Utilization Analysis | Measures current vs. target (85%+) cubic storage efficiency | Capacity planning; expansion-deferral projects |
| Aisle Width Optimization | Models storage density vs. equipment investment for each aisle configuration | All layout engagements with equipment selection |
| Dock Door Planning | Calculates required door count from throughput data, not rule-of-thumb | New construction; expansion; high-throughput DC design |
| Ergonomics-by-Design | Designs pick faces, workstations, and staging for injury prevention | All engagements; specifically food, 3PL, e-commerce |
| AS/IS → TO-BE Modeling | Documents current state forensically before designing future state | Full-facility consulting engagements |
INDUSTRIES WE SERVE
Warehouse Design & Consulting Across 8 Industries
MWS has designed warehouses and distribution centers across virtually every major industry vertical in the Midwest. Core design principles are consistent — but compliance obligations, product handling requirements, and operational constraints vary significantly by industry.
Food & Beverage
FIFO rotation enforcement, USDA/FDA compliance, allergen separation, and compressed retail replenishment windows define food distribution design. MWS designs FIFO-enforcing storage systems (pallet flow, carton flow), USDA-compliant surfaces and drain placement, and dedicated allergen-controlled zones. Named clients include Wells Blue Bunny and Hillshire Farms.
Cold Storage & Refrigerated
Every square foot of unconditioned space costs money. MWS maximizes cold cube utilization with VNA racking, designs thermal breaks at staging zones to control condensation, specifies rapid-open dock doors, and integrates floor heating to prevent frost heave — a specific Midwest design concern. Our crews are cold-storage certified and equipped.
Building Products & Lumber Distribution
Long and heavy product formats require cantilever storage, outdoor/covered coordination, and seasonal volume management tied to construction cycles. MWS has a 22-year exclusive design, sales, and installation relationship with Midwest lumber and building products retailers — one of our deepest areas of applied expertise. Roll-out cantilever systems reduce handling time by up to 80%.
E-Commerce & Fulfillment Centers
Extremely high SKU counts, aggressive SLA windows, and continuous growth pressure require scalable design. MWS designs multi-level pick modules, high-density carton flow for fast-movers, conveyor integration from pick zones to shipping, and layouts that can absorb AMR or AS/RS addition without a complete redesign. Our Effimat VLM systems reduce picking footprint by up to 75% for high-SKU-count slow movers.
Manufacturing & Assembly
Raw material storage, WIP staging, finished goods storage, and lineside delivery — often in the same facility. MWS designs clearly separated material flow paths, lineside KANBAN zone delivery, and overhead crane runway integration from the earliest planning stages. Crane placement must be designed in from the start; adding it later is prohibitively expensive.
Third-Party Logistics (3PL)
3PL layouts must accommodate client turnover. We design modular racking configurations with flexible beam heights, clearly marked client zones with visual management, and WMS-ready location naming conventions that can accommodate new client requirements without full reconfiguration.
Agricultural & Industrial Distribution
Extreme seasonal throughput spikes (harvest-driven demand), large product SKUs, and rural Midwest logistics define ag-sector design. MWS designs seasonal capacity plans modeling harvest-period peaks of 3–5x average volume, dock configurations for large agricultural truck formats, and bulk outdoor cantilever for oversized equipment components. We serve IA, KS, NE, ND, and SD ag operations with specific regional knowledge no national competitor can match.
Automotive Parts Distribution
Tens of thousands of part numbers, varying unit sizes from small fasteners to large body panels, and strict FIFO for warranty compliance. We design mixed-storage approaches: selective pallet rack for large components, carton flow for medium-velocity box picks, bin shelving for small parts, and VLMs for high-value or very small items. Named client: 3M.
COST & TIMELINE
Warehouse Design Cost & Timeline
One of the most common questions from operations managers evaluating a warehouse design consulting engagement is: "How much does this cost — and how long will it take?" No other warehouse design firm in the Midwest publishes direct answers. We do.
What affects the cost of warehouse design?
Project cost depends on your facility size, layout complexity, available information, and the level of design support needed. Equipment and installation also affect the overall budget. We review your goals and project scope with your to prepare a quote tailored to your operation.
How long does a warehouse design project take?
Timing depends on project scope, site conditions, and the information available for planning. Design and installation follow separate schedules, with equipment availability and facility access affecting implementation. Our team will discuss anticipated timing and coordinate the next steps with you.
One Partner. Complete Warehouse Design Through Implementation.
Stop coordinating between a consultant who won't build it and an integrator who won't think about it. MWS does both — from the first data analysis to the last rack bolt — across Iowa, Illinois, Indiana, Michigan, Minnesota, Missouri, Ohio, Wisconsin, Kansas, Nebraska, North Dakota, and South Dakota.
Or call us at 515-635-1555
COMPLIANCE
Design Code Compliance Standards
Every MWS warehouse design is engineered to comply with applicable federal and state regulations, fire protection standards, and building codes. Code compliance is not optional — it affects rack height, aisle width, sprinkler clearances, structural loads, egress requirements, and dock design. Our engineering team maintains current knowledge of all applicable standards and coordinates with local fire marshals and building departments on your behalf when permitting is required.
| Standard | Governing Body | Key Warehouse Design Implication |
|---|---|---|
| OSHA 29 CFR 1910.176 | U.S. Dept. of Labor | Provide safe equipment clearances, clearly marked permanent aisles, unobstructed passageways, and stable material storage. |
| NFPA 13 / ESFR Sprinklers | National Fire Protection Association | Coordinate storage height, rack configuration, and sprinkler clearances with the facility’s fire protection system and applicable design requirements. |
| FM Global Property Loss Prevention | FM Global (industrial insurance) | Incorporate applicable insurer recommendations for storage arrangements, fire protection, and property loss prevention into facility planning |
| IBC (International Building Code) | ICC / Local Jurisdictions | Account for applicable structural, occupancy, and exit requirements when planning warehouse improvements and equipment layouts |
| ANSI MH16.1 (Rack Safety Standard) | Material Handling Industry (MHI) | Specify industrial steel storage racks to meet applicable structural design, testing, and use requirements for the intended storage system |
| RMI (Rack Manufacturers Institute) | MHI | Follow industry guidance for rack planning, installation, use, inspection, and maintenance to support safe storage operations |
| ADA (Americans with Disabilities Act) | U.S. Dept. of Justice | Incorporate accessible routes, entrances, and required clearances, with provisions appropriate to employee work areas and common spaces |
8 Common Warehouse
Design Mistakes That Cost
Operations Real Money
After 50+ years and 1,200+ warehouse design projects across 12 Midwest states, MWS consultants have seen every design mistake a warehouse can make — often more than once. These eight are the most common and most costly.
Automating Before Optimizing
Automation amplifies your process — a broken process, automated, is a faster broken process. Optimize the layout, refine the slotting, fix the process. Then evaluate automation where specific throughput or labor targets justify it.
Designing Aisles Too Narrow
(or Too Wide)
The correct aisle width is driven by your specific equipment fleet. Converting to 7' aisles without reach trucks leaves your team fighting rack damage and congestion. Fourteen-foot aisles with reach trucks wastes thousands of square feet. Design the aisles around the equipment.
Ignoring Slow Movers (C-Items)
C-items — the 40–60% of SKUs driving only 10–20% of picks — routinely end up in prime pick locations that should be reserved for fast movers. The result: A-items buried while C-items occupy the golden zone. Structured ABC slotting analysis is the cure.
Poor Dock-to-Stock Flow
The inbound path from receiving dock to putaway location should be direct and should not cross outbound picking and packing traffic. Cross-traffic congestion disrupts both receiving efficiency and pick performance simultaneously.
No Ergonomics Plan
Heavy lifting from floor-level locations, excessive overhead reach, and awkward product orientation are design choices — and they drive musculoskeletal injuries and workers' compensation claims. OSHA cites warehouse overexertion injuries at an average cost of $50,000+ per incident.
Designing for Today's Volume,
Not Tomorrow's
A layout optimized for today's SKU count may be obsolete in three years. Our capacity planning process models 3- to 5-year growth scenarios and designs modular, scalable layouts to accommodate them.
Skipping the Data Analysis Phase
Redesigning based on intuition and observation rather than SKU velocity data, order profiles, and throughput measurements produces layouts that solve visible problems and miss structural ones. Running the numbers is not optional for a design that will hold up over time.
Treating WMS as an Afterthought
A WMS implemented after a layout redesign will fight the physical design. Pick path routing logic in the WMS needs to match the physical slotting plan. Design the physical and digital layers together from the start.
Why Choose MWS
for Your Warehouse Consultation
50+ Years in Business Since 1979
Founded in Iowa in 1979, MWS has been designing and building Midwest warehouses since before most of our competitors existed. Forty-six years of project experience means we've seen every configuration, every operational challenge, and every implementation complication — and we know how to prevent the ones that can be prevented.
In-House Engineering
& Fabrication
Most warehouse design consultants outsource their engineering. MWS doesn't. Our in-house engineering team — partnered with the same engineering firm for 40+ years — produces stamped engineering drawings, performs structural calculations, and resolves field design challenges without outsourcing delays.
Named Client Portfolio
Our warehouse design and consulting work has been trusted by Hy-Vee distribution centers (Chariton and Cherokee, Iowa), Wells Blue Bunny, Hillshire Farms, 3M, and the National Sprint Car Hall of Fame & Museum. These are real operations that trusted MWS to design and build their most critical infrastructure.
Integrator, Not Just Consultant
When our warehouse design and consulting engagement produces a recommendation, we can implement it. Our installation crews have been executing pallet rack, mezzanine, conveyor, AS/RS, crane, and shelving installations for 50+ years — and they train other material handling companies on proper installation. Call 515-635-1555 to discuss your project scope.
12-State Midwest Depth
National consulting firms serve everywhere generically. MWS knows the Midwest specifically — the cold-climate dock design requirements of Minnesota and North Dakota winters; the agricultural logistics rhythms of Iowa, Nebraska, and Kansas; the heavy-industrial supply chain requirements of Michigan and Ohio; the dense e-commerce distribution markets of Illinois and Indiana.
ISN Certified — Verified Safety & Compliance
MWS holds ISN Certification
(Company ID: 400-690402) — the contractor safety and compliance verification standard used by major industrial, food, and manufacturing companies to vet vendors. Our safety management systems, insurance coverages, and compliance documentation have been independently verified.
12-State Service Area
Iowa
Des Moines, Cedar Rapids, Davenport, Sioux City, Iowa City, Waterloo, Ames, West Des Moines, Ankeny, Council Bluffs, Dubuque, Urbandale
Illinois
Chicago, Rockford, Aurora, Naperville, Joliet, Springfield, Peoria
Indiana
Indianapolis, Fort Wayne, Evansville, South Bend, Hammond
Michigan
Detroit, Grand Rapids, Lansing, Ann Arbor, Flint, Kalamazoo
Minnesota
Minneapolis, St. Paul, Rochester, Duluth, Bloomington, Brooklyn Park, Plymouth, Minnetonka
Missouri
Kansas City, St. Louis, Springfield, Columbia
Ohio
Columbus, Cleveland, Cincinnati, Toledo, Akron
Wisconsin
Milwaukee, Madison, Green Bay, Kenosha, Racine
Kansas
Wichita, Overland Park, Kansas City
Nebraska
Omaha, Lincoln, Bellevue
North Dakota
Fargo, Bismarck, Grand Forks
South Dakota
Sioux Falls, Rapid City, Aberdeen
Can't find your state? MWS takes on projects across the country for the right scope.
Call 515-635-1555 to discuss your project regardless of location.
One Partner. Complete Warehouse Design Through Implementation.
Stop coordinating between a consultant who won't build it and an integrator who won't think about it. MWS does both — from the first data analysis to the last rack bolt — across Iowa, Illinois, Indiana, Michigan, Minnesota, Missouri, Ohio, Wisconsin, Kansas, Nebraska, North Dakota, and South Dakota.
Or call us at 515-635-1555
Frequently Asked Questions: Warehouse Design & Consulting
How long does a warehouse design project take?
Timing depends on project scope, site conditions, and the information available for planning. Design and installation follow separate schedules, with equipment availability and facility access affecting implementation. Our team will discuss anticipated timing and coordinate the next steps with you.
What affects the cost of warehouse design?
Project cost depends on your facility size, layout complexity, available information, and the level of design support needed. Equipment and installation also affect the overall budget. We review your goals and project scope with you to prepare a quote tailored to your operation.
Can you design warehouses for cold storage and frozen food operations?
Yes. MWS provides design and installation services for cooler, freezer, and blast freezer environments. We help plan storage layouts and select equipment around your temperature requirements, product flow, and available space.
Do you serve small and mid-size warehouses, or only large distribution centers?
MWS serves operations of all sizes — from 5,000 sq ft facilities that need a better shelving and racking layout to 500,000+ sq ft distribution centers requiring comprehensive redesign with automation integration.
Our consulting methodology scales with the project: a smaller facility gets a focused, practical engagement that delivers real results without large-firm overhead; a larger facility gets the full analytical depth of our data-driven process. Small businesses and mid-market operations are the core of our Midwest client base.
Our leadership is owner-operated — Tim and Brandy Hennigar, with a combined 50 years of material handling experience — and every project receives the same direct engagement and accountability regardless of size. We also carry in-stock Unarco racking inventory covering 85% of small-to-medium project requirements, enabling 1–5 day pull times and 1–3 business day quote turnaround for standard orders. Call 515-635-1555 — no minimum project size, no minimum order.
What is AS/IS vs. TO-BE analysis in warehouse design?
AS/IS to TO-BE analysis is the professional methodology for warehouse design consulting that ensures your redesign is grounded in documented reality rather than assumptions.
The AS/IS phase involves a thorough forensic audit of your current operation: every rack bay is measured, every pick path is observed and timed, every KPI is captured — throughput per labor hour, order accuracy, cube utilization, dock cycle time, and receiving productivity.
This documentation phase reveals the actual constraints in your operation, which are often different from the perceived constraints. The TO-BE design is the optimized future state built from the gap analysis between the AS/IS baseline and your performance targets, growth projections, and industry benchmarks. Every change in the TO-BE layout is data-justified — not assumed.
Operations that attempt a warehouse redesign without a formal AS/IS assessment consistently encounter the same outcome: the obvious problems are solved, but the non-obvious structural inefficiencies reappear in a different location.
The AS/IS to TO-BE methodology eliminates this failure pattern. MWS has conducted AS/IS assessments across all 12 Midwest states — Iowa, Illinois, Indiana, Michigan, Minnesota, Missouri, Ohio, Wisconsin, Kansas, Nebraska, North Dakota, and South Dakota — for operations ranging from 8,000 sq ft single-room warehouses to 400,000+ sq ft distribution centers. Call 515-635-1555 to start your AS/IS assessment.
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Tell us about your operation — the challenges you're facing, the growth you're planning, and the goals you need to hit. Our warehouse design consultants will respond within one business day with an honest assessment of how we can help.
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