Case Study: Transforming Warehouse Capacity and Efficiency with Scalable Logistics Masterplan

A leading pharmaceutical and personal care manufacturer partnered with Miebach to overcome critical capacity constraints and operational inefficiencies across its logistics network.

Through a data-driven logistics masterplan, the company unlocked 75% additional storage capacity, reduced labor requirements, and established a scalable foundation for future growth - without requiring major facility expansion.

Capacity Constraints Limiting Growth

Rapid growth placed increasing pressure on the company’s logistics infrastructure, creating bottlenecks that threatened both operational performance and future expansion. Existing facilities were no longer aligned with demand, and planned production changes would further reduce available storage capacity.

Warehouses were operating beyond capacity, dealing with limited on-site storage, and additional pallet loss from a new production line created congestion, inefficiencies, safety risks, and constrained scalability. These challenges resulted in rising handling costs, reduced flexibility, and an urgent need for a strategic redesign of the logistics footprint.

Data-Driven Logistics Masterplan

Miebach developed a three-phased logistics masterplan to optimize current operations while preparing the organization for long-term growth. The approach combined operational diagnostics, scenario modeling, and financial validation to ensure both feasibility and stakeholder alignment.

We analyzed current operations, identifying over-utilized storage, insufficient material flows, and immediate improvement opportunities such as layout reconfigurations. Future growth projections, including the impact of the new product line, informed design requirements.

Multiple masterplan scenarios were evaluated, ranging from simple double-deep racking to semi-automated solutions: assessing cost, efficiency, safety, and scalability. Stakeholders selected the most balanced option through collaborative workshops.

The final solution maximized storage while maintaining simplicity. We optimized material flows, designed integrated layouts, and developed a phased implementation plan to minimize disruptions. A comprehensive business case, including CapEx/OpEx and ROI projections, supported the final plan. 

This structured approach enabled the client to confidently select a solution that balanced cost efficiency, operational simplicity, and scalability.

Scalable Capacity and Measurable Efficiency Gains

The solution also delivered significant cost savings, with double-deep racking emerging as the most cost-effective option, reducing CapEx and driving long-term OpEx efficiencies. Optimized material flows cut handling times and congestion, boosting operational efficiency and safety. Improved warehouse layouts reduced labor needs by up to 15%, while phased implementation ensured smooth transitions, minimizing disruption while accelerating time-to-value.

For pharmaceutical manufacturers, logistics constraints can directly impact growth, service levels, and compliance. This case highlights how a structured, data-driven approach can transform existing infrastructure into a competitive advantage.