Leading a Warehouse Consolidation for a Global Flooring Manufacturer & Distributor
Overview
Our client, a global manufacturer and distributor of residential and commercial flooring faced an operational challenge within its U.S. business. With two warehouses in Rome, GA and Savannah, GA, our client needed to streamline their footprint, reduce operating costs, and maintain customer service levels during a complex transition.
To support this effort, the company engaged G1 Consulting to provide strategic guidance and project management leadership. Over the course of six months, G1 worked closely with the client’s leadership team to consolidate operations into a single facility while navigating shifting priorities, budget constraints, and sensitive communication requirements.
Despite these challenges, G1's disciplined planning, execution and collaboration resulted in the project being completed on time, within a reduced budget, and with business continuity in place throughout.
The Challenge
The client set out to consolidate two U.S. warehouses into one to create efficiency and reduce costs. On paper, the objective was straightforward. In reality, the project demanded careful orchestration across multiple fronts:
Timeline: The move had to be completed within six months (between March and August) due to several internal and macroeconomic factors
Budget restrictions: The initial budget was cut in half mid-project, requiring a reassessment of priorities
Stakeholder sensitivities: The client’s leadership team required limited communication about the closure of the Rome facility, reducing opportunities to engage key stakeholders early in the process.
Operational risks: Inventory management, equipment availability, and order fulfillment all carried the potential to directly impact customer experience. Should we say something here about the employee/labor risk (walking out, etc.)?
Our Solution
The client engaged G1 Consulting applied a structured, strategic approach to guide the client through the consolidation.
Strategic Approach
From the start, G1’s role was to create an approach that balanced operational efficiency with minimal customer disruption.
Maintained separate SAP plant IDs for e-commerce and retail operations during the transition
Established a two-week blackout period in August to transfer inventory in a controlled manner
Created customer-specific calendars to set order expectations for key accounts
Resource & Budget Management
Prioritized essential upgrades (lighting, safety measures) over non-essentials (break room renovations)
Postponed capital-intensive purchases such as forklifts, maximizing the use of existing equipment
Change Management & Communications
Designed sensitive internal communications plan for warehouse closure announcements
Delivered customer communications messaging that emphasized strategic benefits to customers
Coordinated EDI changes for customers adjusting to the new shipping point
Program Leadership
Facilitated daily, weekly and ad-hoc stand-ups during the various phases of the project as appropriate
Assembled an internal project team of leaders and assigned each a workstream (operational workstream, finance workstream, etc.)
Tracked key operational metrics including OTIF (On Time In Full), fill rates, and customer feedback throughout the transition.
The Results
By bringing disciplined project leadership, strategic foresight, and pragmatic decision-making, G1 Consulting helped our client successfully consolidate its warehouse operations. The project not only reduced costs but also preserved service quality—demonstrating that even under budget cuts and operational constraints, complex transitions can be executed with precision and minimal disruption.
Inventory moved on schedule with minimal customer disruption
OTIF and fill rates were preserved throughout the transition
Project was completed within a reduced budget
Client executives praised the clear structure, steady execution, and successful outcome
Discover how G1 Consulting delivers disciplined project leadership to help clients navigate complex operational transitions with confidence and precision.