Scalable warehouse growth in South Korea for a fast-growing EV manufacturer

Scalable warehouse growth in South Korea for a fast-growing EV manufacturer

26th February 2026 | 3 min read

The Challenge

A fast-growing EV manufacturer was entering the South Korean market with expected but unpredictable demand. The timing and size of demand spikes were unclear and directly linked to vehicle sales, putting pressure on warehouse space, staffing, and operational planning.

The client needed an operation that could start lean, remain commercially viable, and expand quickly as volumes increased, without compromising service or stability during periods of uncertainty.

The Solution

From day one, our local team worked closely with the client’s leadership and operational teams, building a partnership focused on transparency, flexibility, and shared problem-solving.

From our close collaboration with the client, Unipart was able to implement a scalable operating model designed to grow seamlessly with their success.

Key elements included:

  • Creative warehouse layouts: Storage areas were designed for seamless expansion, carefully balancing immediate storage and productivity needs with the ability to scale small, medium and large storage types quickly, without impacting picking efficiency or disrupting ongoing operations.
  • Flexible space readiness: Pre-configured expansion zones meant sudden surges in volume could be absorbed without disrupting ongoing operations.
  • Data-driven planning: Real-time monitoring of inbound and outbound flows gave early insight into volume changes, enabling proactive adjustments to staffing, storage, and processes.
  • Trained, versatile workforce: Our cross-trained teams were able to step into critical areas when needed, ensuring peak periods were handled efficiently while maintaining operational quality.
  • Supplier and partner alignment: Early engagement and alignment with racking, material handling equipment, consumables, and transport partners ensured that as volumes increased, operations could scale quickly and adapt to changing market conditions without disruption.
  • Adaptive WMS: Warehouse management systems were updated to manage more storage locations and dynamic picking strategies, allowing the operation to remain agile as throughput increased.
  • Close client collaboration: Frequent communication and joint planning sessions ensured decisions were made quickly and operational strategies remained aligned with the client’s evolving needs.

Since go-live in Q1 2025, these combined efforts have enabled the warehouse to double in size, twice. First, six months after launch, and again in Q1 2026, demonstrating the strength of a responsive model delivered by empowered teams working in partnership.

The Impact

What began as a market entry into a new country, has evolved into a major contract extension, reflecting both the client’s rapid expansion, and the strength of the collaborative partnership Unipart has built on site. 

As volumes grew, the operation scaled without losing efficiency. In the first 12 months alone, cost to serve per line reduced by 43%, storage density increased by 191%, and order cut-off times were maintained despite significantly higher throughput.

The team expanded strategically, with experienced staff supporting new colleagues and sharing knowledge across functions. This people-led flexibility strengthened operational coverage and resilience, ensuring the warehouse could absorb demand spikes confidently while maintaining high service standards.

The contract awarding, and subsequent extensions are a clear testament to scalable systems and infrastructure, and to the capability, expertise, and commitment of Unipart’s people.

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By combining operational agility with strong local partnerships and deep automotive expertise, we help businesses entering new markets manage unpredictable growth and build high-performance, sustainable supply chains.

Discover more of our Asia Pacific capabilities and see how we can drive your growth in new and emerging markets.

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