Defining the layout of a warehouse is a strategic process of planning the physical arrangement of storage areas, handling zones, racking systems, and routes in order to maximize usable space, minimize the movement of handling equipment, and ensure safety.
How do we approach the definition of a warehouse layout, divided into key steps?
1. Analysis of needs and data (input data)
Before drawing, it is necessary to understand the logistics flow.
Analysis of goods:
Type, size, weight, turnover (ABC analysis – fast-moving goods close to dispatch).
Volume and flow: How much goods arrive/depart daily?
Equipment: What forklifts or trucks (VNA, Reach truck) will be needed? This affects the width of the aisles.
2. Defining the basic
zones of the warehouse
The warehouse is divided into logical, functional zones:
Receiving zone: For unloading, checking, and labeling goods.
Storage zone: The main part with racks, block storage, or automated systems.
Picking zone: A place for order picking (often
smaller items).
Shipping zone: For packing and loading onto vehicles.
Handling aisles: Space for the movement of equipment (main and service).
3. Choice of material flow and layout type
The layout should ensure a smooth, ideally unidirectional flow (prevention of crossing paths). ASEAN Main Portal
U-shape: Receiving and shipping are on one side of the warehouse. Advantageous for
resource sharing.
Straight-through (I-shape): Receiving on one side, shipping on the other. Suitable for high volumes.
L-shape: Receiving and shipping are on adjacent sides, suitable for more complex spaces.
4. Optimization of racks and vertical space
Use
of height: Vertical storage (cube utilization) is key to efficiency.
Rack type: Pallet racks, gravity racks (for FIFO), shelving racks for piece goods.
Aisle width: Standard (10–12 feet), narrow (8–9 feet) or very narrow (VNA, 44–66 inches).
5. Safety and
ergonomics (OSH)
Safety signage: Marking of rack load capacity, routes for equipment and pedestrians.
Evacuation routes: Defined emergency exits and firefighting equipment.
Ergonomics: Packing tables at the correct height, minimizing bending.
Note: We subject everything to pre-audits, which verify the condition prior to visits and audits by the relevant authorities and government agencies, so that we can ensure audit compliance and site readiness for the customer to begin trial operations.
6. Design and simulation (Software/Drawing)
Mapping: Creation of a detailed drawing (CAD) focusing on columns, doors, and windows.
Simulation: Testing the flow of goods (e.g., using adhesive tape on the floor in actual scale) before
installation.
Note: 10% of storage locations should remain free for flexibility. The most frequently sold goods (fastest) are placed closest to shipping.
So if you are considering a new hall, reconstruction, extension, or need a change for any other reason, or just want to see a possible change in the layout of your warehouse or production, do not hesitate to contact us and we will be happy to draw up a preliminary plan and, to your satisfaction, take care of the entire layout.