Distribution Center Design

Unlock every inch of your building’s potential. Turn to LIDD to design or improve your warehouse. Our smart operating models are driven by science. The difference is data.

Whether you are responding to growth or focused on improving efficiency, our experts work side-by-side with you to design a capital-justified operation.

Deploy capital wisely

From sizing to equipment selection, we base our recommendations on data. Our engineers, analysts, and designers dive deep into your end-to-end operations to ensure every design decision, from layout to sizing, is justified. 

Drive warehouse productivity

Identify operational gaps and inefficiencies to accomplish your KPIs faster. Our work drives throughput and maximizes capacity whether you are reconfiguring an existing operation or building from the ground up.

The difference is data

Others automate out of fear of falling behind. We consider the full range of possibilities, from highly robotic facilities to simple cart-driven operations. Our designs are always driven by operating models informed by millions of lines of data – so you don’t have to guess if that investment is a good idea.

Distribution center design capabilities.

Facility Sizing

Don’t rely on benchmarks or rules of thumb. Size your building and every function within it by relying on a flexible operating model leveraging your data and our hands-on expertise.

Operations Audits

From stock to dock, optimize operations by conducting a thorough analysis of current processes, assessing the gaps and developing comprehensive roadmaps for long-term success.

Materials Handling Design

Select the most-fitting conveyors, sortation, automation, and equipment considering your people, your software, and the unique costs of your operating environment.

Labor Productivity

Take confidence in a fully-integrated operating model. When opening a new facility or transitioning your operations, we define the activities of each role in your four-walls, and optimize their interactions with your systems and the operating flow.

Feasibility Studies

Capital is precious. We protect your spend with data-focused recommendations throughout the distribution center design process.

Automation

The risks of failure are grave. Rely on LIDD to tell truth from fiction to select and implement the right solutions. Our mature relationships with the major global integrators give you confidence that your best interests are driving your project.

Experience the
LIDD way.

Success Stories

Get to know the LIDD team.

Our 100+ industry experts are trusted by clients in more than twenty countries. Let us help you design the distribution center of your dreams.

Charles Fallon

President

Charles has been working as a supply chain consultant since 1998. He has worked with clients at all levels of the supply chain, from manufacturers to retailers, in a wide array of industries including food, pharmaceuticals, garments and construction materials. He has extensive experience in supply chain strategy, technology, facility design & implementation and operations. Charles holds a bachelor’s degree in Mining Engineering from McGill University in Montreal.

linkedin View Full Profile

David Beaudet

Senior Partner

David has worked on a wide range of logistics mandates across North America since 2004. He has been involved in network design, warehouse design and expansion, process re-engineering and the selection of warehouse management systems. His experience lies within all segments of the food industry, pharmaceuticals as well as industrial distribution. David holds a master’s degree in Logistics from HEC Montréal.

linkedin View Full Profile

Jennifer Hall

Partner

Jennifer Hall is a Partner at LIDD and leads its Consulting Practice. With over a decade of experience advising boards and executives, she leads large-scale supply chain transformation initiatives involving multimillion-dollar investment decisions. Jennifer began her career designing warehouses and has since guided clients through network expansions, market entry strategies, and the selection and implementation of new technologies and automation. She has executed numerous operational and digital transformations, with a strong focus on the food & beverage, and consumer goods sectors. Her achievements include redesigning distribution networks for multinational CPG companies, pioneering a new sales channel for a leading grocery chain, and playing a key role in establishing LIDD’s international presence. Jennifer holds a degree in Civil Engineering from McGill University.

linkedin View Full Profile
Our People

Industry Insights

View All

What exactly does your Distribution Center Design service cover?

Designing a warehouse isn’t just about drawing blueprints — it’s about making every square foot work harder.LIDD’s Distribution Center Design service includes facility sizing, layout optimization, automation strategy, and operational modeling. Our engineers draw insights from your historic data  to simulate storage, process flows, and labor performance.This approach ensures that your facility supports future growth, not just today’s volume. Learn more about how our team blends engineering and operations expertise in our supply chain consulting practice.

We’re not hitting our throughput targets, can you help us understand why?

Through our supply chain audit services, we diagnose where productivity is lost — whether it’s layout constraints, slotting inefficiencies, or outdated workflows. Our consultants perform on-site operational audits, model alternative configurations, and identify quick wins that can unlock measurable gains in throughput and labor efficiency. Learn more about our projects in our case studies (link to insights)

How do your consultants help reduce unnecessary capital spending?

Before investing in new automation or real estate, we make sure you actually need it.Our engineers conduct feasibility studies, capacity models, and sensitivity analyses to test every major investment. By aligning design and financial justification early, we’ve helped clients avoid multimillion-dollar expansions by optimizing what they already have. This method — combining engineering precision with supply chain technology consulting — ensures that every dollar invested delivers measurable returns.

How do you approach network design for multi-site or multi-country operations?

Network design starts long before the building phase.We evaluate demand patterns, service levels, and transportation costs across regions to define the optimal number and placement of facilities. Using advanced modeling tools, we simulate how shifting a single DC can affect total landed cost and delivery times. Our experts combine on-the-ground logistics experience with digital modeling to guide expansion decisions. For complex multi-country operations, we also leverage our logistics automation expertise to ensure consistency across sites.

Can you help us validate a third-party design or quote before we commit?

Absolutely. Many clients come to us after receiving proposals from automation vendors or contractors and want a second opinion. As a vendor-agnostic partner, we review technical drawings, assumptions, and cost models to confirm whether the design meets your performance goals – without any bias. Our objective analysis can reveal oversizing, missing constraints, or inflated ROI claims — helping you negotiate confidently. If needed, we provide independent design validation and benchmarking based on our experience in distribution center design projects worldwide.

We’ve already invested in automation, can your team still support us?

Yes. We frequently work with organizations that have existing automated systems but need help fine-tuning or expanding them. Our specialists integrate new processes or technologies with what’s already in place, ensuring compatibility and optimal flow. Whether you’re adding a new conveyor zone or ASRS, we make sure automation works for you and your objectives —. See similar transformation results in our success stories.

Let’s talk distribution design.

Book a Consultation

Are you ready for logistics automation?

Take our readiness quiz to find out!

Begin Assessment