Finding a second floor inside the existing lease

The SKU count had outgrown one pick level, and a second warehouse was the wrong answer.

• Thousands of small, light, high-value lines. The limit was locations, not tonnage.
• A second building would split the team, the stock and the dispatch point.
• The existing building had clear height that one level of shelving barely used.

A mezzanine floor with multi-tier shelving above it, built without stopping outbound.

• Slab and services surveyed first. The floor took the column loads.
• Both levels sized for working headroom once lighting and sprinklers were in.
• Column grid set to keep the main forklift route below clear.
• Built zone by zone across weekends, around the brand's dispatch pattern.

Unused height became a second working level inside the existing lease.

• One stock pool, one dispatch point, one team under one roof.
• The second-building decision deferred.
• No outbound days lost during the build.