From Brownfield to Breakthrough: Evolving Your Operations with Retrofits

from Supply Chain Now · host Supply Chain Now

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 customersResources:Learn more about Bastian Solutions Strategy Guide: Consulting Strategies for Warehouse Distribution Operations: https://info.bastiansolutions.com/warehouse-operations-strategy-guideLearn more about the Hercules Sealing Products Case Study: https://www.bastiansolutions.com/resources/case-studies/industrial-distribution/hercules/?srsltid=AfmBOoqy12r2gfk64cuMt6Heyoz8Ts5lAJwZ-4qAejswM0oZVEuW5pPKConnect 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 Watch and listen to more Supply Chain Now episodes here: https://supplychainnow.com/program/supply-chain-now Subscribe to Supply Chain Now on your favorite platform: https://supplychainnow.com/join Work with us! Download Supply Chain Now’s NEW Media Kit: https://bit.ly/3XH6OVkWEBINAR- Real stories: Fast-tracking value, a pioneering digital transformation with impactful results.: https://bit.ly/4mgp1EWWEBINAR: Real Shipping Stories. Real Money Saved.: https://bit.ly/45PegUmWEBINAR: From Compliance to Impact and Competitive Advantage: How to Decarbonize Your Supply Chain: https://bit.ly/47uXKKoThis episode was hosted by Scott Luton and Deborah Dull and produced by Trisha Cordes, Joshua Miranda, and Amanda Luton. For additional information, please visit our dedicated show page at: https://supplychainnow.com/brownfield-breakthrough-evolving-operations-retrofits-1477 The content in this episode, including all audio, videos, visuals, and graphics, is the property of Supply Chain Now and is protected by copyright law. Unauthorized use, reproduction, distribution, modification, or re-uploading of this content in any form is strictly prohibited without explicit written permission from Supply Chain Now.For licensing inquiries or permissions, please contact us at [email protected]© 2026 Supply Chain Now. All rights reserved. Hosted by Simplecast, an AdsWizz company. See pcm.adswizz.com for information about our collection and use of personal data for advertising.

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This episode is 52 minutes long.

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This episode was published on September 8, 2025.

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