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HYDERABAD'S NO. 1 WAREHOUSE ENGINEERS. LEAN SIX SIGMA PRACTITIONERS. GLOBAL EXPERTISE.

More Storage. Faster Movement. Lower Costs.

We have engineered warehouses and dark stores in the US and Germany, where Indian warehousing is heading. We bring that experience home: more capacity, smoother material flow and lower operating costs, staged so each step pays back on its own. Discreet by default, with diagnostic findings in 3 working days.

Map your warehouse freeSCROLL TO SEE WHAT'S HOLDING YOU BACK ↓

[ what keeps warehouse managers up at night ]

Sound familiar?

The same problems come up in almost every operation, and the industry numbers say they are getting harder. Find yours, and see the service built for it.

  1. We're out of space, and moving isn't an option.

    39%

    of warehouses run at 85% or more of their space at peak; 44% lease extra space to cope

    Source: Peerless Research, 2025

    Usually behind it: Most of the time the building is not full, the layout is. Storage that grew one rack at a time wastes cube and blocks access.

    Service B1Warehouse Layout Design

  2. Trucks are waiting and the docks are jammed.

    38%

    name receiving as the most congested area in the building, up from 20% a year earlier

    Source: Peerless Research, 2025

    Usually behind it: Receiving and putaway run without a standard, so every delivery competes for the same dock space and the same people.

    Service A4Warehouse Capacity & Utilization Audit

  3. I can't get, or keep, enough good people.

    16.6%

    of the peak workforce is now temporary, up from 11.4% the year before

    Source: Peerless Research, 2025

    Usually behind it: When output depends on who is on shift, every new hire is a risk. Clear methods and less walking get new people productive sooner and keep good ones from burning out.

    Service A3Warehouse Operations Audit

  4. The system says it's there. It isn't.

    76%

    of operations now track inventory accuracy as a key metric, up from 70% a year earlier

    Source: Peerless Research, 2025

    Usually behind it: Records fall behind the physical flow at a handful of transactions. Find those, and the counts start agreeing with the shelves.

    Service B3Inventory Accuracy & Control

  5. More SKUs every year, and the stock moves slower.

    6.3

    average inventory turns in 2025, down from 8.2 in 2023, while average SKU counts rose from 7,790 to 9,565

    Source: Peerless Research, 2025

    Usually behind it: Slow movers take the best locations and replenishment rules were set for a smaller range. Both can be reset without new space.

    Service B3Inventory Accuracy & Control

  6. The line stopped. Again. Waiting for parts.

    From the floor

    Usually behind it: Stores usually hear about a shortage after production has already stopped. Kits arrive short, and line-side stock is either missing or piled up.

    Service B4Line Feeding & Plant Stores Design

Figures from the 2025 Warehouse/DC Operations Survey by Peerless Research Group for Modern Materials Handling and Logistics Management (101 operators, August 2025).

Free · Warehouse Capacity Self-Check · PDF

Not sure which of these is holding you back?

Walk your own floor with 30 yes/no checks across storage, flow, picking, inventory and line supply, and see which area to fix first.

Prefer a map? Build your warehouse value stream map free.

Get the free checklist

[ what good looks like ]

How far are youfrom best in class?

The industry's best-in-class marks for the measures behind these concerns. We baseline yours during the assessment, so you know the gap before you commit to closing it.

Inventory count accuracy, by location
≥ 99.5%
Order picking accuracy
≥ 99.68%
Dock-to-stock cycle time
< 3.5 h

Source: WERC DC Measures 2025, best-in-class

[ what we do ]

We improve warehouse space, movement and material availability through practical design, then stay on the floor until the change holds.

[ track record ]

The track recordbehind TvastrOps.

  • MS Industrial Engineering, Purdue University · 4.0 GPA
  • Lean Six Sigma Black Belt
  • Lowe's · Tredence · US manufacturing experience
  • AutoCAD · AnyLogic · Power BI

Results delivered by founder Roshan Mani Rao R in US manufacturing (with Quantumlytix), at Lowe's and at Tredence, before founding TvastrOps. Meet the founder

[ engineering & optimization ]

Four engineering services.One way of working.

Service B1 · Layout, storage and capacity design

Warehouse Layout Design.

Congested storage, difficult access, growing inventory, or an upcoming expansion or relocation.

See this service

Need to assess a building or an operation first? See our four facility audits.

[ the difference ]

A recommendationis not the finish line.

A typical advisory handoff

  • Diagnose the problem
  • Recommend a solution
  • Deliver the report
  • Leave execution to the client
  • Count recommendations delivered

How TvastrOps works

  • Observe and quantify the constraint on the floor
  • Engineer the future state
  • Build and install the change
  • Pilot, train and stabilize with your team
  • Measure operational performance
the Lean Six Sigma improvement cycle
DMAIC
can be bought on its own
Any stage
until the change holds
On the floor
See our Lean Six Sigma method

[ Featured case study ]

Connecting the warehouse to production.

Warehouse, kitting and material-flow redesign at a Fortune 500 manufacturer's largest engineer-to-order site: one warehouse feeding three business lines, rebuilt inside a confined footprint.

Selected professional experience of TvastrOps founder Roshan Mani Rao R at a Fortune 500 manufacturer (with Quantumlytix), completed before TvastrOps. Role: implementation engineer responsible for delivering the stated project results.

Labor utilization
24% → 40%
Structures / month
54 → 120
Daily material shortages
52 → 15

[ Engagement levels ]

Ways to work with us.

Start with a focused assessment and scale the engagement based on what your operation requires. Each level follows DMAIC, the Lean Six Sigma improvement cycle.

  1. Stage 01

    Involvement1 of 3

    Assess

    DefineMeasureAnalyze

    Identify the operational problem before committing to a larger project.

    Includes

    • Initial requirement discussion
    • Site visit or remote assessment
    • Current-state review against a diagnostic checklist built for your operation
    • Key constraints and improvement opportunities
    • Written summary with prioritized recommendations

    Best for businesses that need clarity before making operational or capital decisions.

    Request an Assessment

  2. Stage 02

    Involvement2 of 3

    Design

    Improve

    Develop an engineered solution based on operational data and site requirements.

    Includes

    • Everything included in Assess
    • Project charter and SIPOC (supplier-to-customer map)
    • Pareto and cause-and-effect (fishbone) analysis
    • Layout, capacity or process analysis
    • Simulation or option comparison where applicable
    • Recommended future-state design
    • Implementation roadmap and measurable success criteria

    Best for warehouse redesigns, expansions and defined improvement projects.

    Discuss Your Project

  3. Stage 03

    Involvement3 of 3

    Implement

    ImproveControl

    Support the physical and operational execution of the approved solution.

    Includes

    • Everything included in Design
    • Pilot planning and validation
    • Vendor and execution coordination
    • On-site implementation support
    • SOP development and team training
    • Control plan, post-implementation review and stabilization

    Best for businesses that require support from planning through execution.

    Plan an Implementation

[ pricing ]

How projects are priced.

Each engagement is scoped around the facility, operational challenge and level of support required. We provide a clear proposal covering deliverables, timeline, responsibilities and professional fees before work begins.

  • 01

    Facility size and complexity

  • 02

    Scope and deliverables

  • 03

    Analysis and engineering effort

  • 04

    Implementation and travel requirements

Not sure where to start?

Tell us what is happening inside your warehouse. We will help define the right starting point.

Discuss Your Warehouse

[ free checklist ]

Warehouse Capacity Self-Check

A 30-point checklist to walk your own floor with. It shows where space, movement and stock accuracy are being lost, before you spend on a bigger building or new racking.

  • 30 yes/no checks across storage, flow, picking, inventory and line supply
  • A scoring guide that points to the area to fix first
  • The data to collect before talking to any consultant or vendor

Prefer a map? Build your warehouse value stream map, free, with the report emailed to you.

We’ll use these details only to follow up about your warehouse. No newsletter.

[ start here ]

Let’s talk aboutyour warehouse.

Congested storage. Slow picking. Stock that won’t stay accurate. Lines waiting for parts. Tell us what isn’t holding and we’ll tell you where we would start.