From Brownfield to Breakthrough: Evolving Your Operations with Retrofits

In this episode of Supply Chain Now, hosts Scott W. Luton and Deborah Dull welcome Will Mansard and Ahmed Arif of Bastian Solutions for a practical, field-tested conversation on retrofitting brownfield warehouses and the real cost of doing nothing. They frame retrofits as logistical projects first, unpack why so much existing space goes underutilized, and share how to minimize disruption while upgrading live operations.

They discuss the playbook that works in the real world: start with discovery and reverse engineering when documentation is thin, build a phased mechanical plan, sequence electrical with quick-connect, preassembled components, and treat controls and software as the heart of the system using emulation and thorough testing. With rules one and two both being “get orders out the door,” they stress contingency planning, speaking the customer’s language, and orchestrating equipment, controls, and software to avoid faults and bottlenecks.

Jump into the conversation:

(00:00) Intro

(09:27) What defines a brownfield warehouse site

(12:19) Addressing customer concerns about cost

(15:53) Viewing retrofits as logistical projects

(20:14) Why orchestration matters in automation

(22:44) Critical considerations for warehouse retrofits

(24:26) Setting realistic project expectations upfront

(25:53) Deborah’s favorite retrofit planning framework

(26:36) Minimizing disruption with new technologies

(29:37) Speaking the customer’s language effectively

(32:40) Examples of successful retrofit projects

(40:35) Enterprise-level considerations for customers

Resources:

• Learn more about Bastian Solutions Strategy Guide: Consulting Strategies for Warehouse Distribution Operations: https://info.bastiansolutions.com/warehouse-operations-strategy-guide
• Learn more about the Hercules Sealing Products Case Study: https://www.bastiansolutions.com/resources/case-studies/industrial-distribution/hercules/?srsltid=AfmBOoqy12r2gfk64cuMt6Heyoz8Ts5lAJwZ-4qAejswM0oZVEuW5pPK
• Connect with Will Mansard: https://www.linkedin.com/in/william-mansard-b90a2b25/
• Connect with Ahmed Arif: https://www.linkedin.com/in/ahmedarif001/
• Connect with Deborah Dull: https://www.linkedin.com/in/deborahdull/
• Learn more about Supply Chain Now: https://supplychainnow.com
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