In this episode of The New Warehouse Podcast, Kevin Lawton sits down with Georg Meyer, Independent Director at Assembled Products, to discuss what it truly takes to build a warehouse designed for long-term growth. Based in Iowa, Assembled Products supports manufacturers like John Deere through assembly and kitting services that demand flexibility, accuracy, and operational discipline.
Meyer shares how the company transitioned from leased facilities to a purpose-built warehouse, why they invested in their own WMS, and how thoughtful planning helped them scale without sacrificing efficiency. The conversation offers practical insight for operators looking to align facility design, technology, and growth strategy.
Building a Warehouse Facility Designed to Scale
For Assembled Products, building a warehouse for long-term growth began with recognizing that their existing space no longer fit their future needs. After a period of rapid expansion, the team realized they needed a facility built around how they actually operate. As Meyer explains, “We really realized we were growing out of the facility we were in.” The old space had been designed for distribution, not assembly-driven work.
Rather than reacting to short-term demand, the company made a deliberate decision to invest ahead of growth. “We built 80,000 square foot at a time when we thought we needed 60,000,” Meyer says. That choice proved valuable when demand surged after the pandemic. The additional space allowed the team to consolidate operations, avoid constant reconfiguration, and support larger projects without disruption. Designing for flexibility—rather than immediate need—became a defining factor in their long-term success.
Designing the Warehouse Around Real Operations
A key part of building a warehouse for long-term growth was designing the layout around how work actually happens. Instead of relying solely on outside recommendations, the team combined industry input with hands-on planning. “We turned Excel into graph paper and did a to-scale drawing of what kind of storage we could put in,” Meyer explains. Every aisle, rack, and storage zone was evaluated for usability and future expansion.
The facility includes a mix of wide aisles, traditional racking, and specialized storage to support both small components and larger assemblies. This approach reflects the company’s operational reality. As Meyer puts it, “We really handle a lot of small stuff… nuts and bolts… and then we also got into hoses.” Designing for that mix ensured the warehouse could adapt as product profiles changed. The result was a layout that balanced density, access, and efficiency without locking the operation into a rigid structure.
Building a Warehouse and Supporting Growth with the Right Technology
Technology played a significant role in supporting long-term growth, particularly through the decision to build a custom warehouse management system. With prior experience in software development, Meyer and his team knew what they needed—and what they didn’t. “The effort to customize [off-the-shelf systems] just seemed like a lot to take on,” he explains.
Instead, they focused on building a system that aligned with their workflows and customer requirements. One major driver was traceability. “We wanted something where the system knows at all times what’s on every pallet,” Meyer says. This level of visibility reduced manual work and simplified compliance with customer requirements. Equally important was usability. “We were very, very close to the people who would use it every day,” he adds, ensuring the system supported operators rather than slowing them down.
Key Takeaways
- Building a warehouse for long-term growth requires planning beyond immediate capacity needs.
- Designing around real workflows improves efficiency and flexibility.
- Overbuilding strategically can prevent costly relocations later.
- Custom WMS development can outperform off-the-shelf solutions when aligned to operations.
- Operator input is critical to the success of warehouse and system design.
- Flexibility in layout allows operations to adapt as demand changes.
