Context: A critical branch operation had outgrown a fragmented legacy site, creating business-continuity, health and safety, and capacity risk. A new purpose-built facility was being evaluated as the long-term solution.

Challenge: The issue was not just to secure a new building. The business needed an operationally ready site with the right capacity, layout, automation, labour model, transition plan and future expansion path.

Role: Played a lead role in the operational design and readiness work, including capacity modelling, automation evaluation, labour impact, relocation logic, future-state design choices and go-live planning.

Outcome: The preferred option increased capacity from 48,500 to 60,000 boxes/day in Phase I, created a Phase II pathway to 90,000 boxes/day, reduced FTE requirement from 526 to 278 and set out a 22 month route to go-live.