Manager, Warehouse Network Design & Capacity Planning

The Manager, Network Design, Capacity Planning & Warehouse Expansion Projects is a national role responsible for designing, scaling, and optimizing the company's distribution, warehousing, and copacking network to support profitable growth. Reporting to the VP of Operations, this role owns warehouse network design, capacity planning process, leased buildings vs. using 3PL's recommendations, and end-to-end project management for new warehouse and capacity initiatives.

This role bridges sales forecasting, operational execution, and financial discipline, translating growth plans into a scalable, cost-effective fulfillment and copacking network. Success is measured by improved cost-to-serve, service reliability, capacity readiness, and disciplined execution of network initiatives.

• Own and continuously improve the national network design strategy (divisions/DCs, co-pack facilities, 3PLs partners) to optimize cost-to-serve, lead time, and service levels.
• Develop and maintain network models to evaluate:
  • New sites (greenfield/brownfield), expansions, consolidations, and relocations
  • Customer and product mix shifts and their impact on capacity, freight, and service
  • Alternative fulfillment strategies (direct ship, multi-node, regional stocking, postponement where applicable)
• Recommend service level and coverage standards (e.g., delivery windows, response times, regional service zones) in partnership with Sales/Customer teams.

• Build and manage a standardized capacity planning process across the national network (space, labor, throughput, equipment utilization) with clear assumptions and drivers, to include our 3PL network of locations.
• Develop and maintain capacity models by site for warehousing and copacking operations, including DC Space, Labor, Throughput:
  • Identify capacity constraints and model options for Labor/Shift vs equipment/automation, short-term vs long-term network changes, DC expansion vs 3PL outsourcing:
  • Establish capacity thresholds and triggers tied to forecast volume, utilization, and peak season demand.

• Partner with the Director of Operations-Copack, to lead analytical support for optimal sizing/design related to warehousing and copacking.
• Partner with Procurement and Operations to:
  • Support 3PL and copack RFPs and selection decisions
  • Define network roles for internal sites vs. outsourced partners
  • Establish performance expectations, capacity commitments, and transition plans
• Develop and maintain overflow and surge capacity playbooks using 3PLs.

• Act as a core contributor to S&OP / monthly planning forums, translating demand plans into network and capacity implications.
• Partner with Sales / Sales Ops to assess:
  • New customer wins
  • Volume ramp timing
  • Geographic demand shifts
• Provide clear recommendations on feasibility, timing, and tradeoffs to support leadership decision making.

• Build a standard checklist and requirements document for New Warehouses.
• Own the end-to-end project management for network and capacity initiatives, including:
  • Warehouse expansions or startups
  • New copacking site onboarding
  • Network transitions or rebalancing
  • Major process or throughput improvement initiatives
• Define project scope, timelines, dependencies, risks, and success metrics.
• Coordinate cross functional execution across Operations, IT/WMS, Procurement, Finance, Sales, and external partners.
• Ensure projects are delivered on time, on budget, and with minimal service disruption.
• Track benefits realization against original business cases.

• Build decision quality business cases for:
  • New sites and expansions
  • Lease vs. 3PL decisions
  • Short-term overflow vs. longterm network investments
• Present clear options with cost, service, risk, and scalability of tradeoffs.
• Leverage WMS and operational data to improve utilization of visibility and decision accuracy.
• Standardize assumptions, metrics, and reporting for network and capacity decisions.

• Bachelor's degree in supply chain, Industrial Engineering, Operations, Business, Analytics, or related field (master's preferred).
• 5+ years of experience in network design, capacity planning, supply chain analytics, logistics strategy, or operations planning.
• Demonstrated experience building and presenting business cases (Capex vs. OpEx, build vs. buy, site selection).
• Experience leading cross-functional projects with formal project management practices (scope, schedule, budget, risk management); PMP, CAPM, or similar certification a plus.
• Strong analytical skills; proficiency in Excel (advanced modeling) and data visualization (Power BI/Quick Sight or similar).
• Working knowledge of logistics and distribution economics (transportation modes, warehousing cost drivers, service tradeoffs).
• Experience with network design and planning tools (e.g., Coupa/Llamasoft or similar).
• Familiarity with…