90-Day Hiring Plan for a New Distribution Centre in Australia
Opening a new distribution centre is exciting, but getting your staffing right from day one can make or break your success. A well-structured distribution centre staffing plan ensures your warehouse runs smoothly, orders are fulfilled accurately, and your team is ready to scale when demand spikes.
In Australia’s competitive logistics sector, businesses across Sydney, Melbourne, and Brisbane face ongoing challenges: skills shortages, high turnover rates, and constant pressure to meet tight delivery deadlines. That’s why having a strategic 90-day hiring plan isn’t just helpful, it’s necessary.
According to the National Skills Commission, warehousing and logistics roles remain among Australia’s most consistently advertised occupations, with forklift operators and pick packers in persistent demand. This ongoing skills shortage makes early workforce planning essential for new distribution centre launches.
This guide walks you through a proven three-phase approach to building a high-performing warehouse team from scratch, covering everything from core roles to compliance requirements.
Real-World Example: 90-Day DC Launch in Western Sydney
In 2024, we supported the launch of a 12,000m² distribution centre in Western Sydney, supplying 38 workers within the first 6 weeks, including high-reach forklift operators, pick packers, and an onsite supervisor. By week 10, the facility was processing 4,500+ orders per day with a pick accuracy rate above 99.2%.
Early workforce planning, structured onboarding, and pre-booked peak coverage were critical to preventing labour shortages during the ramp-up phase.
Days 1-30: Lay the Foundation
The first month is about establishing your core team and setting up systems that support long-term success.
Define Your Staffing Requirements
Start by mapping out exactly what roles you need to operate efficiently. For most distribution centres, this includes:
1. Forklift operators (counterbalance, high reach, order pickers)
2. Pick packers (RF scanning, voice picking, pick-to-light)
3. Receiving and dispatch staff
4. Inventory controllers
5. Warehouse supervisors
6. General labourers
Consider your operational hours, expected order volumes, and warehouse layout when calculating headcount. A common mistake is underestimating the number of multi-skilled workers needed to cover breaks, absences, and demand fluctuations.
Partner with a Specialist Labour Hire Agency
Traditional recruitment can take months, and hiring mistakes are expensive. Partnering with a specialist labour hire agency gives you immediate access to vetted, experienced workers who understand warehouse operations.
Look for agencies that offer:
1. Thorough screening processes including face-to-face interviews
2. Pre-employment fitness checks
3. Reference verification and licence checks
4. WHS compliance and safety training
5. Onsite management support
In Australia, agencies like Tetris Labour Hire specialise in blue-collar recruitment for warehousing and distribution, supplying workers across Sydney, Melbourne, and Brisbane who are ready to perform from day one.
Recruit Your Core Permanent Team
While casual and temporary workers bring flexibility, your permanent team forms the backbone of your operation. Start by hiring:
✓ Warehouse manager
✓ Operations supervisor
✓ Senior forklift operators
✓ Lead inventory controller
These roles require industry experience and leadership capability. Start recruitment in weeks 1-2 to allow time for interviews, reference checks, and onboarding before operations ramp up.
Establish Safety and Compliance Systems
Before anyone starts work, ensure your site meets all WHS requirements. This includes:
✓ Comprehensive site induction programs
✓ PPE provision and inspection protocols
✓ Emergency procedures and evacuation plans
✓ Incident reporting systems
✓ Toolbox talk schedules
Compliance isn’t optional. Australian warehouses face strict regulations, and early investment in safety culture prevents costly incidents later.
All distribution centres must comply with Safe Work Australia guidelines and relevant state-based WHS legislation (such as SafeWork NSW, WorkSafe Victoria, and Workplace Health and Safety Queensland). Employers are legally responsible for providing a safe working environment, conducting risk assessments, and ensuring licensed operation of high-risk equipment such as forklifts.
Days 31-60: Build Your Flexible Workforce
By month two, your permanent team should be settling in. Now it’s time to add flexibility and scale your workforce strategically.
Bring in Casual and Temporary Workers
Casual workers allow you to manage demand fluctuations without overcommitting to permanent headcount. Use labour hire to fill:
✓ Peak period roles (seasonal surges, promotional events)
✓ Shift coverage (sickness, leave, unexpected absences)
✓ Specialised tasks (RF pick packing, quality assurance, rework)
A smart distribution centre staffing plan typically maintains a 60:40 or 70:30 ratio of permanent to casual staff, giving you stability while maintaining operational flexibility.
Train and Integrate New Workers
Even experienced workers need time to learn your systems. Allocate time for:
1. Site-specific training (pick paths, scanning workflows, dispatch procedures)
2. Equipment familiarisation (warehouse management systems, RF scanners)
3. Safety protocol reinforcement
4. Supervisor shadowing for first shifts
Proper training reduces error rates, improves productivity, and strengthens worker retention. Warehouses that invest in onboarding typically see 30-40% better performance in the first 90 days.
Track Performance From Day One
Set clear KPIs for your team:
1. Pick accuracy rates
2. Orders per hour
3. Safety incident frequency
4. Attendance and punctuality
5. Quality control metrics
Regular performance reviews help identify top performers (who may be candidates for permanent roles) and address issues before they impact operations.
Days 61-90: Optimise and Scale
The final month is about refining your workforce, addressing gaps, and preparing for growth.
Review Workforce Performance
By day 60, you should have clear data on what’s working and what isn’t. Look at:
✓ Which roles have the highest turnover?
✓ Are there skill gaps affecting productivity?
✓ Is your permanent-to-casual ratio optimal?
✓ Do you have enough multi-skilled workers?
Use this information to adjust your staffing mix. If forklift operators are in short supply, consider upskilling existing staff or bringing in additional certified operators through labour hire.
Offer Temp-to-Perm Pathways
Some of your best casual workers may want permanent roles. Offering temp-to-perm opportunities:
✓ Reduces recruitment costs
✓ Retains workers who already know your systems
✓ Builds loyalty and improves workplace culture
✓ Strengthens team stability
This approach is especially valuable in tight labour markets where skilled warehouse workers are highly sought after.
Plan for Seasonal Peaks
Australian distribution centres face predictable demand spikes: Black Friday, Christmas, EOFY, and summer sales. Start planning your peak season strategy now by:
1. Forecasting additional headcount requirements
2. Pre-booking casual workers through your labour hire partner
3. Scheduling training sessions ahead of demand surges
4. Reviewing overtime policies and shift structures
Warehouses that plan 6-8 weeks ahead for peak periods consistently outperform those that scramble at the last minute.
About Tetris Labour Hire
Tetris Labour Hire has operated in Australia’s blue-collar recruitment sector for over 30 years, supporting logistics, warehousing, manufacturing, and transport clients with scalable workforce solutions. Our team works directly with operations managers, HR leaders, and site supervisors to implement structured staffing strategies that reduce turnover and improve productivity from day one.
Why Tetris Labour Hire?
Building a high-performing distribution centre team requires more than just filling shifts. It demands experienced workers, rigorous screening, and ongoing management support.
Tetris Labour Hire has been helping businesses across Sydney, Melbourne, and Brisbane build reliable warehouse teams for over 30 years. As winners of the Parramatta Local Business Award, we’re recognised for our commitment to quality staffing and client satisfaction.
What sets us apart:
✓ Extensive end-to-end onboarding including face-to-face interviews, fitness checks, and licence verification
✓ Specialist recruitment for warehousing, transport, logistics, and manufacturing
✓ Onsite management solutions with regular safety meetings and performance check-ins
✓ 3-month guarantee on permanent placements
✓ Access to forklift operators, pick packers, inventory controllers, and warehouse all-rounders
Whether you’re opening a new distribution centre or scaling an existing operation, we supply the workforce solutions you need to succeed.
Ready to Build Your Distribution Centre Team?
A strategic distribution centre staffing plan makes all the difference between a smooth launch and costly delays. With the right mix of permanent staff, flexible casual workers, and a trusted labour hire partner, your warehouse can hit the ground running.
Contact Tetris Labour Hire today to discuss your staffing needs:
📞 1300 TET RIS (1300 838 747)
✉️ info@tetrislabourhire.com.au
📍 Sydney | Melbourne | Brisbane
Let’s build a team that powers your distribution centre forward.