Designing a warehouse is essential for a company to efficiently store, arrange, and oversee its inventory or resources. If the warehouse layout design is not well planned, time will be wasted on basic tasks like finding goods, moving through aisles, and keeping track of inventory. This could lead to higher operational expenses and ineffective processes that directly impede the supply chain, delaying the delivery of goods to customers. The optimal warehouse design varies based on a company’s requirements; however, a well-thought-out layout will always focus on space utilisation, productivity enhancement, and safety prioritisation.
What is a warehouse layout?
The arrangement of space within a building is known as warehouse layout design. This design determines the way in which materials, employees, and machinery are arranged in the area in order to optimise the production and distribution processes. Specifically, warehouse planning considers the layout of each part of the warehouse, including storage, selecting, packaging, and office areas, as well as the arrangement and utilisation of necessary tools in these areas. A carefully planned design should also consider the dimensions and forms of objects to be stored, as well as any possible dangers or barriers that could hinder mobility.
Components of a Warehouse Layout
Every effective warehouse, no matter its size or industry, requires a few essential components. The arrangement of these parts creates the foundation of the entire warehouse design. Also, the arrangement within each element affects the process’s effectiveness.
Receiving Area and Storage Area
The receiving section is where incoming deliveries are unloaded, logged, and organised. Placing this area next to the storage area will facilitate the transfer of incoming goods to their designated spots.
Inventory is stored until it is required for order fulfilment. The storage space needs to be arranged efficiently and configured for easy access, with direct access to both the receiving and packing sections.
Packing Area and Shipping Area
Orders are packaged for shipping in the packing area after they are picked. Packing zones need to improve speed and precision while maintaining worker comfort and safety. Orders ready for shipping are processed in the shipping department. This space needs to be within the warehouse and typically linked to a shipping bay on one end, with direct entry to the packing section on the opposite side.
Warehouse Layout Considerations
When creating a warehouse layout, each business must take into account its specific factors to ensure it meets their requirements. Here are some things to remember:
Type of Operation and Products Being Stored
The flow of traffic and the required storage type depend on the type of operation. For instance, a manufacturing facility linked to a warehouse may need a different design compared to a distribution centre.
The type of storage required will also depend on the products being stored. For instance, a small hummus producer may require dry goods storage as well as cold storage for perishable ingredients.
Available space and equipment requirements
If the warehouse is not custom-built, the amount of space will impact the warehouse layout design. Efficiency should be maximised in every corner of a warehouse.
Different shapes and sizes of racking and shelving systems can be customised to suit the products and storage methods in use. Customising is essential for creating personalised storage solutions that cater to your individual requirements.
Workflow Implementation and Safety Regulations
The design of a warehouse affects the flow of goods, staff, and equipment within the warehouse, as well as the effectiveness of these movements. By creating a layout that nurtures the workflow while decreasing bottlenecks, a warehouse can enhance efficiency and lower mistakes. Efficiency optimisation is essential.
Warehouses are required to follow a range of safety regulations. When planning a warehouse layout, it is important to include defined exit routes for emergencies, designated areas for portable fire extinguishers, and ensuring there is adequate clearance in aisles and at loading docks.
Warehouse layout design types
Most warehouse layouts use either a U-shaped, I-shaped, or L-shaped design, all of which can improve efficiency. The ideal choice is determined by the amount of space and the operational requirements of the company.
U-Shaped
This layout is in the form of a half circle, also known as a “U.” Receiving and shipping are located next to each other at opposite ends of the “U,” and storage is located towards the back of the warehouse. This particular layout is more suitable for smaller structures; however, there may be truck traffic issues if the loading and unloading docks are situated too closely together.
I-Shaped
This warehouse is in the form of a straight line, resembling an “I.” Shipping is located at one extreme, receiving at the opposite end, and storage is situated in between. Every item flows in one direction, similar to a production line. This simple layout is beneficial for warehouses handling large quantities of orders.
L-Shaped
This design adheres to the form of a 90-degree angle, also known as an “L.” Storage is located in the corner, with shipping and receiving bays positioned at both ends of the “L” shape. Warehouses shaped like the letter L can be beneficial for companies that engage in cross-docking, or the rapid transfer of goods from one truck to another.
Conclusion
Creating an ideal warehouse arrangement is an intricate procedure that can be simplified with the appropriate strategy and tools. By maximising space, enhancing accessibility, preparing for changes, utilising appropriate technology, and placing worker safety as a priority, any company can design an effective warehouse layout that suits its specific requirements. At Krost Shelving & Racking, our commitment is to assist you in maximising efficiency in your warehouse operations through our personalised storage options and professional advice.