Tesla’s Toronto distribution centre faced rising demand and SKU complexity. The existing narrow-aisle setup couldn’t accommodate oversized parts or increased throughput.

The goal: optimize space and process flow for the next three years without disrupting live operations.

Smart Space Optimization

Tesla needed to maximize capacity without expanding its footprint. We installed 7,500 pallet positions across 190,000 sq. ft. using VNA racking, double-deep configurations, and oversized modular racking.

Dedicated high-velocity picking zones improved order flow for small parts, while custom back-stop beams and wire decks enhanced safety and flexibility.

Seamless Integration

Working in a live facility required meticulous planning and coordination. Our team executed phased installation to maintain uptime and confirmed compatibility with existing systems through a pre-engineering review.

Every element was designed to meet OBC/NBC code requirements, ensuring compliance and operational confidence.

Performance That Pays Off

The impact was immediate: throughput increased, KPIs improved, and labour efficiency rose across the board. Tesla deferred relocation by three years, saving significant capital costs, and achieved full ROI within two years.

Teams reported positive feedback on improved organization and ease of training, making the transition smooth and effective.

Photos of a new racking system installed in an automotive warehouse.
The new racking system at Tesla’s Toronto distribution centre

“The racking system provided by Platform 1 has been completed on time and on budget. The impact on Tesla operations has been positive and well-received. Platform 1 demonstrated professionalism and expertise throughout the entire process, delivering a solution that exceeded Tesla expectations. We are extremely satisfied with the results and would confidently recommend their services to any organization seeking storage capacity, workflow and professionalism.” – Tomo Iwata, Tesla

By combining smart design, compliance assurance, and phased execution, Platform 1 helped Tesla unlock capacity, improve efficiency, and delay costly relocation — proving that engineered solutions can transform operational challenges into long-term advantages.

Ready to streamline production?

Contact us today to discover storage solutions engineered for your business.