How to Create an Efficient Warehouse Layout

Most warehouse managers are looking for ways on how to make use of company resources to their full potential, productivity, inventory control, and meeting the future demands of products on their warehouses. 

Probably the reason behind such shortcomings is having an inefficient warehouse layout in the first place. Whether you’re planning a new manufacturing business or designing your warehouse space to be more effective and efficient, a sound layout is essential. 

There are different types of warehouses, such as manufacturing warehousing, private warehousing, distribution centers, and others; however, this article focuses only on the manufacturing warehouse. Here is some advice from Southern Dock Products of Houston, Texas, a division of DuraServ Corp, the largest distributor in the world for the leading manufacturers of dock equipment and hi-speed doors, on how to create an efficient warehouse layout.

Step 1: Know and Understand Your Business Requirements in Detail

First and foremost, knowing your business requirements will help you conceive your facility design; however, you need to analyze your books deeper. The well-defined data will give you better insights on what to expect in terms of stock’s turnover, returns, and stock volumes, which is the initial point for establishing the internal and external layout of a warehouse, storage capacity, and space requirements needed.

Step 2: Create a Schematic Layout

Every lay-outing design starts off with a scheme. You can do it yourself manually, using the traditional pen and paper system, or with the latest computer technology designing tools for a faster and easy way, whatever is convenient for you.  

If you do it manually, you can start off by using a copy of your warehouse blueprint, usually handled by your landlord if you are renting the space. Next, create and draw up your schematic layout on a graph paper with a 1 to 1 grid layout. Microsoft's Word program and Pinterest.com can print graph paper designs.  

Professionals use the latest AutoCAD program and CLASS, one of the leading ‘off the shelf’ software, which is economical enough but would take time to learn by yourself. Or you can try Inkscape, a free and open-source graphic design program fully capable of creating vector graphics, and compatible with image editing software. You can also try online layout tools such as FloorPlanner, which can create 2D and 3D floor plans, and SmartDraw, which can draw any type of chart.

For pencil and paper schematic, attach it to a piece of poster board while a piece of tracing paper overlays above. This lets you sketch and draw with shelving and equipment arrangements while estimating spaces in-between different layouts. 

If you are using computer layout tools as stated above, you’ll be able to create designs or use templates for an easy and convenient way of lay-outing your desired warehouse, then print it out on large paper sizes from A0, A1, A2, or A3 using plotter machines.   

Important Reminder:

Always work with accurate measurements. In warehouse space planning, every inch counts. Use a rolling tape measure, or better an engineering tape measure for more accurate and easy measurements.

Bear in mind to maximize and utilize every space properly; for example, when stocking on your warehouse, always optimize the use of vertical space. Efficiently organize your stocks with less frequently-purchased items higher up, in narrow aisles, or in the harder-to-access areas of your warehouse.   

Be detailed when drawing your sketches, and do not forget stationary figures like supports, office area build-outs, etc. Next, make a printed copy of your schematic layouts with measurements drawn to scale.

For more samples of warehouse layout schemes, you can search at Google.com or Pinterest.com websites for ideas and more conceptualized schemes, or you can check out www.camcode.com samples at https://www.camcode.com/asset-tags/warehouse-organization-charts/. 

Step 3: Space Planning

Planning for the layout of your warehouse space is very vital, which is mostly based on the functionality of your warehouse or the designer’s choice.

Warehouse design layouts vary with several conceptualized designs to suit the needs of a certain business. Basically, warehouses are composed of different areas, such as receiving area, picking /staging area, inventory area, outbound shipping, and cross-docking areas. 

To simplify the complexities of warehouse elements, this article summarized them into four vital elements for space planning: 

A.      Equipment and Workspace Areas

B.      Production Zones and Workflow Areas

C.      Storage Areas

D.      Miscellaneous Warehouse Options

A. Equipment and Workspace Areas

Layout first by starting off on prioritizing the things that take up most of your space, or the key units of your production workspace. In the manufacturing business, first prioritize equipment and production workspaces then storage spaces.

There are different types of equipment used to execute various tasks. The equipment used in a warehouse may be mobile (for example, a Pallet Jack, Fork Lift, or cart), or stationary (for example, a sorter). In doing your layout, consider the equipment dimension and design specifications to properly allocate the space it would accommodate.

Another important space lay-outing to consider is traffic flow. Be wary of intermodal traffic, usually where intermodal chassis have different heights than standard trailers and may cause an obstructed rear impact guard, which is one of the warehouse hazards to look out for.

In this connection, anticipate major traffic blockages by eliminating traffic barriers during rush hours. This happens when organizing old shipping boxes or unpacking items, and keeping stacking large barriers within the traffic zones. Traffic flow should be free and needs to be constantly keeping things out of the main traffic area.

B. Production Zones and Workflow Areas

The key elements involved are materials, workers, and products/goods that move around. This area or zone is highly important in terms of safety measure awareness, and in such a way, space layout is vital. 

In manufacturing, there is material and personnel movement around equipment and space allocation should be properly laid out. Creating organized workstation spaces according to the specific task and worker reduces workplace injuries and hazards, which in turn increase ergonomic benefits with improved productivity.

C. Storage Areas

Consider first what you’re storing; by then, you can determine your storage space with the shelving and other accessories. Product dimension dictates the space you need to allocate.

For a more highly effective storage space allocation, create segments in the warehouse that are well-defined. For example, returned-products area and the stock area should be separated with clearly marked labels, in order not to confuse stocks from pending products. Moreover, shipping and receiving areas must be separated far from each other, in order to avoid confusion and improper staging of freight merchandise.

D. Miscellaneous Warehouse Options

Warehouse space lay-outing should consider the dimensions of storage and workspace equipment, such as assembly tables or packing stations, shelves, racks, work desks, and office fixtures. Accurate measurement of the above items is essential in any warehouse space lay-outing.

Selecting shelving and storage solutions depends on the nature of your operation, the size and volume of products that flow through your facility, and other considerations. 

A notable suggestion when planning warehouse space layout for aisle space is making sure to allocate an adequate room in between aisles. When moving products around, there should be enough area to maneuver, thus avoiding delays and hazards towards the workers and inventory.

Even though you feel that you may have covered almost all aspects for your warehouse layout, it is still best to open to the idea of getting professional expert advice. With the ever-changing warehouse designs through the years, as large distribution centers have moved away from single channel to multi-channel inventories and even smaller warehouses have begun to automate many operations, our Houston Texas Loading Dock Products and design specialists are ready to help clients with warehouse layout designing needs.

Call Southern Dock Products now at our Houston, TX number, (713) 868-5443, or at our toll-free number, 1-800-994-2361, for our Houston, TX service staff to answer to any warehouse or loading dock inquiries.

You can directly make Service Request at https://www.southerndockproducts.com/service-request or you can also personally visit our Loading Dock Design in Houston Texas, and check out our Loading Dock Products in Houston Texas.