In today’s fast‑moving supply chain environment, the warehouse is no longer a static storage box, it’s a strategic asset. Whether expanding capacity, consolidating sites, or building a new facility from the ground up, the design decisions you make today will shape operational performance for years to come.
At Davies & Robson, we support organisations across retail, manufacturing, and distribution to plan, design, and implement warehouses that deliver efficiency, resilience, and long‑term value. Based on our experience leading major logistics transformation programmes, these are the core considerations every business should evaluate when planning a new warehouse.
Space Utilisation: Designing for Maximum Capacity
Optimising the footprint is fundamental. Effective warehouse design considers building height, aisle configuration, racking layout, and the balance between storage and operational space. Our consultants’ model multiple layout scenarios to ensure every square metre works hard, without compromising safety or throughput.
Workflow & Process Design: Engineering Smooth Flow
A warehouse must support the seamless movement of goods. That means analysing inbound, storage, picking, packing, and despatch flows to eliminate bottlenecks and unnecessary travel. Davies & Robson use process mapping and simulation tools to design layouts that reduce congestion and increase productivity.
Selecting the Right Storage Systems
From pallet racking and shelving to mezzanines and automated storage solutions, the choice of storage system must reflect SKU profiles, handling characteristics, and service requirements. We help clients evaluate the trade‑offs between flexibility, density, and cost to select systems that support both current and future needs.
Safety & Security Built into the Design
A well‑designed warehouse protects people, products, and assets. This includes lighting, ventilation, fire protection, access control, CCTV, and secure yard layouts. Davies & Robson ensure all designs meet regulatory requirements while embedding best‑practice safety principles from day one.
Material Handling Equipment Integration
Forklifts, conveyors, AMRs, AGVs; the equipment you choose must align with your operational strategy. Our team ensures the warehouse layout supports efficient equipment movement, safe operating zones, and optimised loading and unloading areas.
Technology & Automation Readiness
Modern warehouses rely on digital tools to drive accuracy and efficiency. Whether integrating a Warehouse Management System (WMS), barcode scanning, RFID, or automation, Davies & Robson help design facilities that are technology‑ready and capable of scaling with future innovation.
Planning for Future Growth
A warehouse should not only meet today’s requirements but also tomorrows. We build scalability into every design, from modular racking to expansion zones and flexible process flows, thus ensuring your investment remains viable as volumes, channels, and customer expectations evolve.
Regulatory Compliance
From building codes and fire regulations to environmental standards and accessibility requirements, compliance is non‑negotiable. Davies & Robson manage these considerations throughout the design process to de‑risk projects and avoid costly re-designs.
Supporting Employee Comfort & Productivity
A productive workforce needs a well‑designed environment. Break areas, restrooms, temperature control, noise management, and ergonomic workstations all contribute to employee wellbeing. We help clients design facilities that attract and retain talent while improving operational performance.
Sustainability & Energy Efficiency
Sustainable warehouse design is now a commercial imperative. Energy‑efficient lighting, insulation, HVAC systems, solar power, and rainwater harvesting can significantly reduce operating costs. Davies & Robson incorporate sustainability principles into every project to help clients meet ESG goals and reduce long‑term costs.
Why Organisations Choose Davies & Robson
Designing a warehouse is a complex, high‑stakes undertaking. Davies & Robson bring:
- Independent, expert advice
- Data‑driven modelling and scenario analysis
- Deep operational and engineering expertise
- End‑to‑end support from concept to go‑live
- A proven track record across multiple sectors
Whether you’re planning a new facility or rethinking your existing network, our consultants ensure your warehouse is designed for performance, resilience, and future growth. Give Davies & Robson a call to discuss how we can help design your future warehouse or indeed, improve your existing one.
