How One Furniture Importer Increased Warehouse Capacity 70%

Supply chains are under intense cost pressures right now. 

Geopolitics, long lead times, and unpredictable demand swings are forcing companies to front-load inventory. Which in turn is causing massive inefficiencies across supply chains - you're stuck with more inventory than your operations were designed to handle.

The typical solutions all cost more money: lease additional warehouse space, pay premium freight rates, or accept expensive external storage fees.

You're essentially paying extra to solve problems created by inefficiency.

But one East Coast furniture importer, serving big box retailers like Walmart and Home Depot, took a different approach. 

Instead of throwing money at the problem, they looked inward at their existing operations. Their warehouse was "full" and they were bleeding $3-5 million annually in demurrage charges.

Their solution wasn't finding more space - they found 70% more capacity in the warehouse space they already had, with payback under one year.

I interviewed Steve Hopper, founder of Inviscid Consulting, who led this transformation.

Here's how his team helped the importer transform inefficiency into opportunity, and what you can learn from their experience.

What's Inside:

• Why capacity isn't space

• Finding hidden inefficiencies

• Avoiding data traps

• SKU analysis framework

• Four storage methods (doubled capacity)

• $5M to sub-year payback

• The $125K mistake

• Project timeline

• 8 lessons

• Redesign vs expansion framework