As Zalapack’s daily order volume approached the 300-package mark, their existing warehouse layout became a critical friction point. The primary pain points included:

• Workflow Bottlenecks: Without dedicated, purpose-built packing stations, employees lacked a streamlined process for sorting, packing, and labeling, causing unnecessary movement and wasted time.
• Missed Deadlines: The cumulative effect of an unoptimized floor plan meant that despite the team's best efforts, order processing was consistently falling behind daily shipping cutoffs.
• Workforce Fatigue: The lack of ergonomic warehouse furnishings made it difficult for workers to maintain an efficient pace throughout their shifts, directly impacting productivity and morale.