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Network Optimisation and Strategic Warehouse Reviews

Network Optimisation and Strategic Warehouse Reviews
Written by:
Trace Insights
Publish Date:
Jan 2026
Topic Tag:
Strategy & Design

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Network Optimisation and Strategic Warehouse Reviews

A practical Australia–New Zealand guide to lowering logistics cost, lifting service, and future‑proofing your supply chain

If your supply chain feels like it’s working harder than it should, you’re probably right. In Australia and New Zealand, distance is unforgiving, freight markets can turn quickly, and warehouse labour and industrial property constraints don’t politely wait for your next budgeting cycle. Add customer expectations for faster delivery, channel complexity, and constant disruption—from weather events to port variability—and suddenly “the network” isn’t just a diagram on a slide deck. It’s your margin.

That’s where network optimisation and strategic warehouse reviews come in.

Done well, they’re not academic exercises or software-only projects. They’re practical, decision-ready programs that answer questions like:

  • Are we holding inventory in the right places for the way customers buy today (and will buy tomorrow)?
  • Do we have the right number of warehouses—and are they in the right locations?
  • Are we using our existing sites as effectively as we could, or are we paying for inefficiency twice (labour and space)?
  • What service levels can we realistically promise by region—and what do they cost?
  • How do we plan for growth, volatility, sustainability targets, and risk without overbuilding?

This article breaks down what network optimisation and strategic warehouse reviews actually involve, common traps organisations fall into, and a clear pathway to decisions you can implement. It’s written for leaders who need outcomes, not buzzwords—whether you’re a COO, supply chain director, logistics manager, CFO, or property and procurement lead.

Why this topic matters right now in Australia and New Zealand

There’s a reason “we should review the network” keeps resurfacing in leadership meetings: small inefficiencies compound fast in ANZ.

A few realities tend to hit at once:

1) Geography makes mistakes expensive
In Australia, sending freight the wrong way—especially across long east–west corridors—turns into real dollars quickly. In New Zealand, inter-island movements, terrain, and the concentration of population in a handful of centres create their own set of trade-offs.

2) Customer expectations have shifted (and don’t shift back)
Even in B2B, lead times are compressing. In B2C, next-day delivery expectations vary by region, but the direction of travel is clear: customers want speed, accuracy, and visibility.

3) Warehousing constraints are structural, not temporary
Labour availability, automation lead times, and industrial property realities mean you can’t “just add a shift” or “just lease another building” without consequences. Capacity planning has to be deliberate.

4) Inventory is a service lever—and a cost sink
Network decisions directly drive inventory positioning and safety stock. A network that looks cheap on transport can quietly blow out working capital and obsolescence.

5) Resilience and sustainability have moved from nice-to-have to board-level
The network you design needs to cope with disruption and support emissions reduction efforts—without sacrificing service.

In short: network and warehouse decisions are no longer periodic tidy-ups. They’re strategic.

What network optimisation actually means (beyond the buzzword)

Network optimisation is the disciplined process of designing (or redesigning) how product flows from suppliers to customers across your distribution footprint—balancing service, cost, inventory, risk, and constraints.

It typically covers:

  • Warehouse locations and roles (national DC, regional DCs, cross-docks, forward stocking locations, micro-fulfilment, etc.)
  • Customer allocation rules (which customers ship from which sites, and when that changes)
  • Transport mode and lane strategy (linehaul, metro, regional carriers, intermodal/rail where applicable, coastal shipping, direct-to-store, etc.)
  • Inventory positioning and policy (cycle stock vs safety stock; postponement; decoupling points)
  • Capacity planning (space, docks, automation throughput, labour, peak handling)
  • Service design (lead times by region, cut-off times, delivery frequency, DIFOT targets)
  • Constraints and realities (property, labour, technology readiness, transition risk, supplier lead times)

A key point: optimisation doesn’t mean chasing the mathematically cheapest network. It means selecting the best network for your strategy—and being explicit about trade-offs.

For example, an “optimal” model might suggest consolidating warehouses to reduce fixed cost. But if that adds two days to regional delivery and triggers lost sales, the cheapest network on paper becomes the most expensive decision you can make.

The best network work brings the full picture together: cost, service, inventory, and risk—then turns it into a decision leaders can back.

What a strategic warehouse review is (and why it’s not just a site walk-through)

A strategic warehouse review looks at each facility (and your portfolio overall) and asks: Is this warehouse fit for purpose today, and will it still be fit for purpose in three to five years?

It’s broader than operational auditing. It typically considers:

1) Role clarity: what is this site meant to do?

  • Is it a national reserve and replenishment hub, or a fast-response regional node?
  • Is it bulk storage, pick/pack, kitting, returns processing, or value-added services?
  • Is the operating model aligned to demand and order profiles?

2) Capacity and constraints

  • Storage capacity (pallet positions, racking, floor utilisation, height use)
  • Throughput constraints (receiving, replenishment, picking, packing, dispatch)
  • Dock and yard capacity
  • Peak management readiness (seasonal volumes, promotions, project work)

3) Layout and flow

  • Do travel paths make sense, or has the site evolved into a patchwork?
  • Are fast movers genuinely “fast” in layout placement, or just fast in the ERP?
  • Are you balancing efficiency with safety and congestion risk?

4) Labour model and productivity

  • Shift design and coverage
  • Indirect vs direct labour mix
  • Training and cross-skilling
  • Labour availability risk by region

5) Technology, data, and control

  • WMS capability and configuration
  • Slotting logic and replenishment rules
  • RF discipline and inventory accuracy
  • Visibility and reporting that supports daily management

6) Automation and mechanisation options (where appropriate)

A review should be practical: what is feasible in your building, with your workforce, and with your volume profile—not “automation because it’s trendy”.

7) Property and compliance

  • Lease terms, expansion options, and landlord constraints
  • Building suitability (clear height, column spacing, sprinkler, floor load)
  • Safety, chain of responsibility, and site compliance requirements
  • Sustainability opportunities (energy efficiency, solar readiness, waste management)

The output of a strong warehouse review is not a generic scorecard. It’s a set of prioritised initiatives, a capability roadmap, and clear recommendations on whether to fix, reconfigure, expand, relocate, or exit.

Network optimisation vs warehouse reviews: which comes first?

This is where many organisations get stuck.

Here’s a practical way to think about it:

  • If you suspect the number and location of warehouses is wrong, start with network optimisation. Otherwise you risk spending money improving a site you shouldn’t keep long-term.
  • If you’re confident the footprint is broadly right but performance and capacity are off, start with a strategic warehouse review to unlock improvements quickly.
  • If you have significant change ahead (new channels, acquisitions, major growth, new service promise), do them as a combined program: network scenarios inform the role of each site, and warehouse reviews confirm feasibility and investment needs.

In many ANZ organisations, the best approach is iterative: model network options, pressure-test them with site reality, then refine.

Common triggers that signal it’s time for a review

If any of these feel familiar, you’re in the zone where network optimisation and warehouse review work pays off:

  • Freight cost has crept up faster than sales growth—and no one can point to one clear cause.
  • Service is inconsistent by region (metro is fine; regional is a constant firefight).
  • You’re expediting more often “to protect the customer experience”.
  • Inventory is rising, but availability still isn’t where it needs to be.
  • Warehouses feel full all the time (or swing between empty and congested).
  • You’ve added channels (e-commerce, marketplaces, wholesale, projects) and the operating model hasn’t caught up.
  • Your 3PL arrangement is up for renewal, or performance has plateaued.
  • You’re facing a lease expiry or a property constraint and need a decision, not a debate.
  • Leadership wants resilience—yet the network depends heavily on one site or one corridor.

These triggers are rarely solved with a single initiative. They’re symptoms of a network that has drifted away from the current business reality.

A practical framework: how to run network optimisation and warehouse reviews that lead to decisions

Below is a proven, decision-focused pathway. It works whether you’re running the work internally, partnering with a specialist, or blending both.

Step 1: Define the outcomes (and the non-negotiables)

Start by making trade-offs explicit.

  • What service levels matter—and where?
  • What cost categories are in scope (transport, warehousing, inventory, capex)?
  • What constraints are fixed (must keep a site, must maintain 2-day service, union requirements, automation already ordered)?
  • What’s the planning horizon—3 years, 5 years, 10 years?
  • What risks are unacceptable (single points of failure, change complexity, transition downtime)?

This is where alignment happens. Without it, teams build models to answer different questions and argue about “the numbers” instead of making decisions.

Step 2: Build a baseline you can trust

A baseline is the “current state” that the model and recommendations anchor to.

You’ll usually need:

  • Customer order history (by region, channel, order lines, cube/weight)
  • SKU velocity profiles and storage requirements
  • Inventory policies and stockholding by site
  • Transport spend by lane and mode (including accessorials)
  • Warehouse costs (labour, occupancy, fixed vs variable, 3PL charges where relevant)
  • Service performance data (OTIF/DIFOT, lead times, fill rates)

A common pitfall: organisations start scenario modelling before baseline validation. If the baseline is wrong, every scenario becomes a debate.

Step 3: Identify scenarios that reflect real strategic choices

Good scenarios are not “move DC from Sydney to Melbourne because the map looks neat.”

They reflect genuine options, such as:

  • Consolidation vs regionalisation
  • One national DC + cross-docks vs two national DCs
  • Dedicated e-commerce fulfilment vs shared facilities
  • Direct-to-store vs hub-and-spoke replenishment
  • Increased use of intermodal for long-haul lanes (where feasible)
  • Changes to delivery frequency and cut-off times
  • Forward stocking for critical SKUs in remote regions
  • Alternative property choices if a lease is expiring

Scenarios should be limited enough to be decision-ready—typically a handful of credible options plus a stretch scenario for learning.

Step 4: Evaluate scenarios on total value, not a single metric

A strong decision framework looks across:

  • Transport cost (linehaul + last mile)
  • Warehousing cost (fixed + variable)
  • Inventory impact (safety stock changes, working capital)
  • Service impact (lead times by region, ability to meet cut-offs)
  • Resilience (single points of failure, disruption exposure)
  • Practicality (property availability, transition risk, implementation time)

The key is to present outcomes in a way leaders can weigh, not just a “winner” declared by a model.

Step 5: Conduct strategic warehouse reviews to validate feasibility

This is the bridge between modelling and reality.

For shortlisted networks, warehouse reviews confirm:

  • Can the site physically handle the new role and throughput?
  • What capex or reconfiguration is required?
  • What changes to process, labour model, or automation are needed?
  • What’s the transition pathway without breaking service?

This is also where hidden constraints surface—dock congestion, yard limitations, unsafe flows, or WMS limitations that a spreadsheet won’t tell you.

Step 6: Build a business case that survives scrutiny

A decision-ready business case should include:

  • Clear assumptions and sensitivity testing (fuel, labour, demand growth)
  • One-off transition costs (dual-running, relocation, fit-out, redundancy, onboarding)
  • Capex and payback where relevant
  • Risks, mitigations, and a realistic timeline
  • A phased roadmap if full change is too risky to execute at once

Leaders don’t just approve a network design. They approve change. So the path matters.

Step 7: Implementation planning (the part most programs underestimate)

Even the best design fails if implementation is vague.

Implementation planning should cover:

  • Property strategy (search criteria, lease negotiation support, fit-out requirements)
  • 3PL strategy (tendering, contracting, governance)
  • Systems and data readiness (WMS/TMS impacts, master data, slotting)
  • People and change management (roles, training, safety, consultation requirements)
  • Cutover planning (inventory migration, parallel runs, contingency plans)
  • KPI framework (what success looks like in the first 90 days and the first year)

ANZ-specific considerations that materially change network decisions

Network models can look clean until the local realities show up. In Australia and New Zealand, several factors commonly influence the “right” answer:

Australia: distance, state-based realities, and east–west trade-offs

  • East coast density vs national reach: Many networks are naturally biased toward the east coast. But national customers (or mining, projects, and remote accounts) force a different calculus.
  • Perth and WA: Servicing WA from the east can be viable for some SKUs and service promises, but it can also create persistent cost and service pain if expectations aren’t aligned.
  • Regional and remote delivery: Lead times, carrier availability, and delivery frequency constraints can change what “good service” means outside metro corridors.
  • Intermodal and linehaul strategy: There are cases where shifting mode or redesigning linehaul schedules is more valuable than moving warehouses.

New Zealand: concentration, inter-island complexity, and resilience

  • Population concentration: Demand clustering can support fewer sites, but service expectations and geography still require careful planning.
  • North vs South Island strategy: Inventory positioning and inter-island movements need to be deliberate—especially if you serve time-sensitive customers.
  • Resilience considerations: Business continuity planning can have a stronger influence when geographic separation and disruption risk are factored in.

Trans-Tasman supply chains

If your supply chain crosses the Tasman, the network conversation becomes not just “where are the warehouses?” but:

  • where do you decouple inventory,
  • how do you manage lead times and variability,
  • and what service promises are achievable without carrying excessive buffer stock.

These are design questions, not firefighting questions—so they’re best addressed through structured network work.

What “good” looks like: signs you’ve got the right network and warehouse strategy

When network optimisation and warehouse reviews have been done properly, you typically see:

  • A clear definition of warehouse roles (and fewer “hybrid” sites doing everything poorly).
  • Fewer urgent expedites and less reactive freight spend.
  • Improved service consistency by region, even if absolute lead times vary.
  • Inventory positioned intentionally, with clearer policies and fewer “just-in-case” decisions.
  • A realistic capex roadmap—targeted investment rather than scattered fixes.
  • Better cross-functional alignment: supply chain, sales, finance, and property all working from the same design logic.
  • KPIs that connect network decisions to customer outcomes, not just internal efficiency.

Common mistakes (and how to avoid them)

Mistake 1: Optimising transport in isolation

Transport-only optimisation can accidentally increase warehouse handling, inventory, or service failures. The network must be evaluated end-to-end.

Mistake 2: Treating warehouse constraints as “operational issues”

If a site cannot physically meet future throughput, no amount of process discipline will fix it. That’s a strategic constraint, not a coaching opportunity.

Mistake 3: Overbuilding complexity

More nodes can improve service—but they can also increase inventory, management overhead, and execution risk. A simpler network that’s well-run often beats a complex network that’s fragile.

Mistake 4: Underestimating transition risk

Moving inventory, onboarding a new 3PL, or changing site roles can temporarily degrade service. Transition planning and dual-running costs must be included.

Mistake 5: Letting property drive the strategy

Cheap rent isn’t cheap if it adds linehaul cost, increases labour turnover, or forces poor warehouse flow. Property is part of the solution—not the strategy.

How Trace Consultants can help

Network optimisation and warehouse reviews sit at the intersection of strategy and execution. The value comes from making the right calls—and then making them real without breaking service.

Trace Consultants supports organisations across Australia and New Zealand to design, validate, and implement distribution and warehousing strategies that balance cost, service, inventory, and risk.

Here are the practical ways Trace can help:

1) Network strategy and scenario optimisation

  • Clarifying your service promise by channel and region
  • Building a baseline you can trust (cost-to-serve, freight, warehousing, inventory)
  • Designing and testing credible network scenarios
  • Translating outputs into leadership-ready trade-offs and decisions
  • Sensitivity testing so you’re not hostage to a single assumption set

Outcome: a network direction you can confidently take to the executive team—supported by logic, not just instinct.

2) Strategic warehouse reviews that link operations to strategy

  • Assessing whether existing sites are fit-for-purpose for current and future roles
  • Identifying throughput constraints and practical improvement options
  • Developing a targeted capex and operational improvement roadmap
  • Validating feasibility of proposed network scenarios in the real world

Outcome: clear recommendations on where to invest, where to reconfigure, and where a site is simply the wrong tool for the job.

3) Business case development and investment planning

  • Building a robust financial model including transition costs and benefits
  • Creating staged roadmaps (e.g., quick wins now, footprint changes later)
  • Supporting board-ready documentation and investment logic

Outcome: decisions that survive finance scrutiny and translate into action.

4) 3PL and operating model support (where relevant)

If your network direction involves outsourcing changes or new capabilities, Trace can support:

  • Defining requirements and service levels
  • Running tender and evaluation processes
  • Designing governance and performance frameworks that stick

Outcome: a partner model that supports performance, not just contract compliance.

5) Implementation support—turning the design into reality

  • Transition planning (inventory migration, cutover design, contingency planning)
  • Process and layout redesign
  • KPI frameworks and operational cadence design
  • Change management support, ensuring teams can adopt new ways of working

Outcome: benefits realised in operations, not parked in a PowerPoint file.

The best time to involve support is often earlier than you think—before teams become committed to a preferred answer based on partial data, or before property deadlines force rushed decisions.

Practical questions to ask before you start

If you’re scoping network optimisation or a warehouse review, these questions will save time (and rework):

  1. What decision do we need to make in the next 3–6 months?
    Be specific: renew a 3PL, choose a new DC, redesign service promise, plan capex, etc.
  2. Which KPI are we trying to change—and what’s the current baseline?
    Cost-to-serve, OTIF/DIFOT, lead time, inventory days, pick rates, damage, claims.
  3. Where do we believe the biggest lever is—transport, warehousing, inventory, or service design?
    Often it’s a mix, but one area usually drives the need.
  4. What constraints are real and fixed vs assumed?
    A “must keep this site” assumption often turns out to be negotiable—or time-bound.
  5. What does success look like operationally after the change?
    New network design without an operating model is just a map.

FAQ: Network optimisation and warehouse reviews

How often should we review our distribution network?

Many organisations benefit from a light-touch network refresh annually (to keep assumptions current) and a deeper review every 2–3 years, or whenever major triggers occur (growth, channel change, lease events, acquisition, sustained service issues).

What data do we need to start network optimisation?

At minimum: shipment history by customer and location, order profiles, SKU velocity, freight spend and lane data, warehouse cost and capacity data, inventory positioning, and service performance expectations. The best programs focus first on baseline accuracy, then scenarios.

Can we optimise the network without changing warehouses?

Yes—sometimes the biggest wins come from changing allocation rules, linehaul schedules, delivery frequency, inventory policies, or warehouse roles. But if a site is fundamentally constrained emphasising throughput or property suitability, footprint change may be unavoidable.

How do sustainability goals fit into network decisions?

Sustainability can be addressed by modelling emissions alongside cost and service, selecting lower-emission transport options where feasible, reducing unnecessary kilometres, and right-sizing inventory and warehousing energy profiles. The key is to include it as a decision criterion early—not as an afterthought.

What’s the difference between a warehouse audit and a strategic warehouse review?

An audit often checks compliance and operational performance against standards. A strategic review connects site reality to future business needs: role clarity, capacity, expansion feasibility, technology and automation readiness, and whether the site belongs in the future footprint at all.

Closing thought: the best networks are designed, not inherited

Most distribution networks aren’t intentionally designed end-to-end. They evolve—one new customer, one warehouse extension, one “temporary” overflow site that becomes permanent.

Network optimisation and strategic warehouse reviews give you a chance to step back and ask: What network do we actually need now—and what will we need next? Then they give you a way to make those decisions with confidence.

If your organisation is facing property deadlines, rising logistics costs, inconsistent service, or growth that your current footprint can’t comfortably absorb, it’s worth taking a structured look. And if you want that work to lead to practical, implementable decisions—Trace Consultants can help you move from analysis to action, with an approach grounded in the realities of Australian and New Zealand supply chains.

Ready to turn insight into action?

We help organisations transform ideas into measurable results with strategies that work in the real world. Let’s talk about how we can solve your most complex supply chain challenges.

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