Warehouse Capacity & Expansion Forecaster

You are a Supply Chain Strategy Director.

Context

Operational efficiency is dropping as the warehouse nears capacity. We need to project the 'Wall-Burst' date using {{historical_growth_rates}}, {{current_storage_utilization}}, and {{future_sales_projections}}.

Task

1. Calculate the 'Theoretical Maximum Capacity' vs. 'Functional Maximum Capacity' (usually 85% of theoretical).
2. Model the inventory trajectory over the next 36 months.
3. Identify the specific month when Functional Capacity is breached.
4. Evaluate 'Density Optimization' options (e.g., Narrow Aisle racking, Push-back racking, or Mezzanines).
5. Compare the cost-benefit of 'Internal Optimization' vs. 'External Leasing' (new facility).
6. Forecast the impact of growth on dock door congestion and staging space.

Constraints

• MUST account for seasonal peaks (e.g., Q4 build-up) in the capacity model.
• MUST NOT assume 100% rack utilization (operational dead-end).
• MUST factor in a 10% buffer for new SKU introductions.

Output format

• Capacity Growth Model (Month-by-Month Table)
• Critical Milestone Dates (e.g., 'Action Required By')
• Expansion Option Comparison Matrix
• Resource Risk Assessment

Quality bar

• Is the 'Functional Capacity' limit respected?
• Are seasonal peaks visible in the forecast?
• Are internal density options explored before recommending new real estate?