A high-performing supply chain starts with smart supply chain network design. Whether you’re scaling operations, reducing fulfilment times, or integrating automation, your network design and facility design decisions are critical to long-term success.

As consumer expectations rise and logistics become more complex, businesses can no longer afford inefficient layouts or poor location planning. Often it is not about building bigger, it’s about knowing how to build smarter.

Why network and facility design matters

A warehouse or distribution centre (DC) is the beating heart of your logistics operation. And your broader supply chain network design determines how efficiently you move products from suppliers to customers.

Get it right, and you unlock:

  • Reduced transport costs
  • Faster order fulfilment
  • Greater flexibility to scale
  • Better space utilisation
  • Improved customer satisfaction

Get it wrong, and you’re looking at delayed deliveries, over-investment in the wrong assets, and costly redesigns.

Supply Chain Network Design: the strategic backbone

Supply Chain Network Design involves determining the optimal number, location, and role of facilities within your supply chain. It answers questions like:

  • Where should warehouses be located to reduce delivery times and freight costs?
  • Should you centralise distribution or operate from multiple regional hubs?
  • How do you balance inventory levels across sites?

Effective network design involves:

  • Cost-to-serve modelling to evaluate logistics costs across locations.
  • Transport network alignment to streamline last-mile delivery and inbound freight.
  • Scenario planning to future-proof against volume growth or supplier shifts.
  • Multi-site coordination to integrate DCs, cross-dock facilities, and satellite warehouses.

With the right network in place, your business can flex to demand, expand with ease, and service customers more competitively.

Use facility design to make every square metre work harder

Once your network is in place, the next step is facility design. Developing a physical space that drives efficiency, speed, and safety.

Modern facility design focuses on:

  • Right sizing the building footprint to meet current and projected needs.
  • Optimising storage density through vertical space, racking systems, and smart layouts.
  • Designing efficient flows from receiving to dispatch, reducing touchpoints and travel time.
  • Incorporating automation-ready layouts that can support future MHE and robotics.

Key elements of effective supply chain network design include:

  • Dock & door planning to manage throughput without congestion.
  • Ceiling height optimisation to support high bay racking or ASRS.
  • Workstation and mezzanine integration to maximise floor utilisation.
  • Safety zoning to protect workers and maintain compliance.
  • Office and amenity layout that supports collaboration and staff wellbeing.

Future Proofing Your Infrastructure

The best-designed facilities are built factoring the future. That means:

  • Planning for modular expansion and scalable fit outs.
  • Integrating data-driven insights into space planning.
  • Designing around automation compatibility even if deployment is phased.
  • Ensuring flexibility to shift between B2B and B2C fulfilment as needed.

Whether you’re launching a new facility on a Greenfield site or upgrading an existing operation, investing in quality design pays dividends across the entire supply chain.

Supply Chain Network Design: From concept to go live

Comprehensive network and facility design requires more than just blueprints. It takes project leadership, technical expertise, and alignment across multiple stakeholders.

An integrated approach typically includes:

  • Site selection and feasibility analysis
  • Master planning and layout modelling
  • Procurement and contractor engagement
  • Construction and fitout oversight
  • Regulatory approvals and legal coordination
  • Technology integration and testing
  • Operational go-live support

A single point of accountability ensures that timelines, budgets, and performance benchmarks are met without surprises.

Automation and material handling integration

Automation is a necessity for competitive fulfilment. A well-designed facility accounts for:

  • Conveyor and sortation systems to streamline goods movement.
  • Goods-to-person robotics to reduce manual picking time.
  • Automated storage and retrieval systems (ASRS) to maximise space and accuracy.
  • WMS and data system integration for real-time visibility and control.
  • Racking and inventory solutions that enhance productivity and safety.

These systems must be considered during the supply chain network design phase to ensure seamless implementation and avoid expensive retrofits later.

The importance of clear project execution in supply chain network design

Even the best designs can fall short without rigorous execution. That’s why project governance is essential, including:

  • Real-time project tracking
  • Transparent budgeting and cost control
  • Collaborative stakeholder engagement
  • Proactive issue resolution
  • Formal site handover and training

Consistency, communication, and visibility throughout the lifecycle make the difference between success and frustration.

Key Benefits of Strategic Network & Facility Design

By investing in best practice supply chain network design and facility design, businesses unlock:

  • Lower operating costs through smarter layouts and fewer transport moves
  • Faster fulfilment with efficient workflows and streamlined infrastructure
  • Scalability to support growth and adapt to market shifts
  • Reduced risk through compliant, automation-ready builds
  • Greater resilience in supply chain performance and continuity

When to consider a redesign

Your facility or supply chain network design may need review if:

  • You’ve outgrown your current space or network capacity
  • You’re expanding into new markets or channels
  • Service levels are declining due to congestion or inefficiency
  • You’re introducing automation or new technologies
  • Transportation costs are rising disproportionately
  • You’re considering a Greenfield or Brownfield development

Network and facility design is not a one-off decision, you are making a foundational investment in your business strategy. Whether optimising your current footprint or planning your next move, strategic design offers a powerful lever for performance and growth.

Need help with your supply chain infrastructure?

Talk to our Melbourne network and facility design experts to discover how we can help you build smarter, scale faster, and reduce cost-to-serve.