Manufacturing and Warehouse Greenfield Site Relocation

Problem

A remote branch was the largest and most profitable among 12 nationwide locations. However, the existing facility was outdated and undersized, limiting operational efficiency and growth. A greenfield relocation was deemed the best solution, rather than redesigning or upgrading the existing site.

Scope and Deliverables

Stoke led the full planning and execution of the relocation, ensuring minimal disruption to business operations. The key deliverables included:

Stock Optimisation Strategy: Analysed slow-moving and dead stock, reducing potential write-offs.
Review and Establish Future-State Business Processes: Engaged stakeholders to develop new ways of working and optimise workflows.
Workflow Optimisation: Achieved a 10% reduction in shopfloor labour costs through natural attrition in a 25-person workforce.

Outcomes

Stock Optimisation: Reduced slow and dead stock write-off from $500K to only $40K.
Space Optimisation: Created 25% more spare shelf space, reducing clutter and improving warehouse workflows.
Operational Performance: Stock turnover doubled post-relocation.

ROI Assessment

Against program and project consultancy and management costs, the average ROI is estimated at 500% with the savings below identified:

ROI Area	Metric	Estimated Value
Stock Optimisation	Reduced write-off from $500K to $40K	$460K saved
Workflow Optimisation	10% shopfloor labour cost reduction (natural attrition)	$150K+ annually
Increased Stock Turnover	Stock turnover doubled post-relocation	$3M+ efficiency gains
Risk Mitigation	Avoided warranty exposure	$250K+ in potential liability

Ken Davis

Stoke Consulting

Ken’s senior line and consulting exposure has spanned many decades in metals and automotive manufacturing and distribution, oil & gas and IT services in national and international roles. Ken has delivered direct accountability for effective change strategies, program execution and continuous improvement and innovation in Australia and internationally.