Warehouse Design Optimization
Space Utilization
The physical layout of storage racks, aisles, and staging areas. This includes building dimensions and cube utilization (vertical space).
The strategy for how products are stored and retrieved (e.g., receiving or dispatch strategy, inventory throughput).
Physical
(Infrastructure / Layout)
Operational
(Processes / Activities)
Pick & Dispatch
System
The equipment used, such as conveyors, storage systems, automated guided vehicles (AGVs), sorting machines, and manual picking.
The methodology or workflow of picking orders (e.g., batch picking, zone picking, wave picking) and the sequence of dispatching goods.
Accessibility
The width of aisles, number and location of dock doors, and clear pathways for equipment and personnel movement.
Procedures ensuring that frequently accessed inventory is positioned in easily reachable primary pick locations to reduce travel time.
The spatial arrangement that minimizes travel distance and bottlenecks (e.g., a well-designed U-shaped flow).
Key performance indicators (KPIs), metrics, and continuous improvement methodologies (e.g., Lean principles) used to measure and optimize work.
Efficiency
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Flow Optimization
The physical path design of goods from receiving to storage, picking, and shipping without crossing paths (e.g., straight-through or U-flow layouts).
SOPs and software (WMS) that direct the sequence of tasks and movement of goods to maintain a steady, smooth and safe flow.
Physical Infrastructure such as guardrails, bollards, clearly marked pedestrian walkways, proper lighting, and fire suppression systems
Safety protocols, training programs, operational procedures for equipment usage, and adherence to regulatory compliance (e.g. DOSH)
Safety
The tangible hardware and infrastructure, such as barcode scanners, RFID Readers, and warehouse automation systems.
The software and data management systems, such as a Warehouse Management System (WMS), algorithms and the integration of data analytics for decision making
Technology
Available floor space for future expansions, modular racking systems, and infrastructure capacity (power) to support additional automation or plant
The flexibility of the WMS and operational strategies to handle increase throughput (e.g. ability to add extra shifts, hire seasonal staff or manage a larger throughput of SKUs).
Scalability
