Slotting Strategies for Greenfield vs. Brownfield Distribution Centers

When it comes to optimizing warehouse operations, slotting is one of the most impactful strategies you can implement. But not all distribution centers are created equal. Whether you're working with a Greenfield site (brand new, built-from-scratch) or a Brownfield facility (an existing site with legacy systems), your slotting strategy needs to reflect the environment you're operating in.

Greenfield Distribution Centers: A Blank Canvas

Greenfield DCs offer the luxury of designing your warehouse layout and slotting strategy from the ground up. With no legacy constraints, you can build the most efficient system possible, if you have the right tools.

Key Challenges:

• Pressure to “get it right” from day one

• Limited feedback loops until operations begin

How Slot3D Helps:

Simulation Before Implementation - Slot3D allows you to simulate different slotting strategies before your facility goes live. You can model SKU velocity, layout variations, and travel paths to make informed decisions without physical trials.

Design Around Your Growth Plan - Slot3D supports slotting strategies based on forecasts orders, enabling your new DC to scale efficiently as business ramps up.

Zone Strategy & Optimization - Define pick zones, slot product according to ergonomic access points during the design phase to maximize productivity from the start.

Brownfield Distribution Centers: Legacy, Limitations & Opportunity

Brownfield sites come with their own set of challenges, often outdated slotting plans, evolving product mixes, and inefficient processes that have been "good enough" for years.

Key Challenges:

• Legacy slotting strategies not aligned with current demand

• Space constraints and bottlenecks

• Higher labor and travel time costs due to poor SKU placement

How Slot3D Helps:

Data-Driven Optimization - Slot3D ingests your historical order and SKU data to identify inefficiencies in your current slotting strategy and recommend improvements backed with economic value.

Quick Wins Without Full Redesign - Slot3D highlights low-effort, high-impact changes you can make to improve efficiency and reduce total operational costs.

Measure ROI on Every Move - Visualize and calculate the ROI of proposed slotting changes before making them, so you know exactly what to expect from your investment.

Different Starting Points, Same End Goal - Slotting Strategy for Distribution Centers

Whether you’re building from scratch or modernizing an existing warehouse, the goal is the same: reduce travel time, increase throughput, and boost operational efficiency.

Slot3D is built to handle both greenfield and brownfield scenarios by giving you visibility, control, and confidence in your slotting strategy.

Ready to See the Difference?

Slot3D brings intelligent slotting to any facility, new or old. Schedule a Demo or Learn more to see how we can support your next warehouse project and create the right slotting strategy for your distribution centers.