Process Excellence Lead

Role & responsibilities

Own the end-to-end design of standardized dark store layouts, bin/rack planograms, and pick-path strategies from a central function enabling any dark store, regardless of size or shape, to be set up for fast picking, high space utilization, and operational consistency, without requiring bespoke redesign at each site

Key Responsibilities
Layout & Planogram Design

• Develop and manage a central repository of standardized dark store blueprints categorized by size and format (e.g., under 1,000 sq ft, 1,000-2,500 sq ft, and over 2,500 sq ft). This ensures any facility can rapidly implement a proven design with minimal site-specific adjustments.
• Create planograms defining rack/bin/shelf placement, fast-mover vs. slow-mover zones, cold storage/frozen zones, and packing/staging areas optimized for picker speed rather than customer browsing.
• Adapt standard templates to site-specific constraints (irregular shapes, column placement, entry/dispatch points) while preserving core design principles.

Pick Path & Space Optimization

• Define optimal pick-path logic (e.g., zone picking, batch picking) to minimize picker travel time and maximize orders-per-hour in a high-SKU-density, high-order-frequency environment.
• Optimize slotting SKU placement based on order velocity, basket-pairing, and pick frequency to reduce congestion in narrow aisles typical of dark stores.
• Set aisle widths, rack density, and staging/dispatch area sizing to balance SKU capacity against picker and last-mile rider flow.

Standardization & Governance

• Publish central design standards, SOPs, and playbooks so regional/ops teams can set up new dark stores consistently without central intervention for every site.
• Define approval criteria for any local deviation from standard templates (e.g., odd-shaped properties, shared-space constraints).
• Maintain version control of templates as designs are improved based on performance data.

Data-Driven Iteration

• Use dark store performance metrics (picker stress, open picklists, active pickers, open units, avg wait time, orders/hour) to identify underperforming layouts and refine templates.
• Partner with Ops and Analytics teams to run before/after comparisons on layout changes.
• Conduct periodic store walk-throughs/audits (in person or via regional teams) to validate that designs perform as intended on the ground.

Cross-Functional Collaboration

• Work with Store Launch, Supply Chain, WMS/IT, and Ops teams to ensure layouts are technically and operationally feasible before rollout.
• Provide layout and planogram inputs during new dark store site selection and launch planning.
• Train regional design/ops points-of-contact on applying central standards correctly.

Required Qualifications

• Bachelor's degree in Industrial/Systems Engineering, Supply Chain, Retail/Operations Management, or related field (Master's preferred).
• 48 years of experience in warehouse/micro-fulfillment layout design, space planning, or slotting quick-commerce, dark store, or dense fulfillment-center environments strongly preferred.
• Hands-on experience with space-planning tools (e.g., AutoCAD, or equivalent) and WMS-linked slotting logic.
• Working knowledge of pick-path optimization methods for small-footprint, high-order-density fulfillment environments.
• Strong analytical skills comfortable working with operational data (orders/hour, picker productivity, space utilization) to justify design decisions.
• Experience designing for multiple dark store formats/sizes rather than a single standard footprint.

Preferred candidate profile

• Experience standardizing layouts across a large, distributed dark store network from a central function.
• Familiarity with WMS systems and how layout/slotting decisions integrate with pick/pack/dispatch workflows.
• Prior exposure to hyperlocal or quick-commerce last-mile fulfillment operations.

Key Performance Indicators

• Reduction in average pick time / picker travel distance post rollout of new layouts.
• % of dark stores operating on standardized (vs. custom) layout templates.
• Space/SKU utilization rate (usable storage vs. total footprint).
• Reduction in picker stress / open picklist backlog linked to layout changes.
• Time to design and roll out a layout for a new dark store (design-to-launch cycle time).