Layouts - Index
could a great new warehouse layout do for YOU?
Sample warehouse layout - #1
- large scale drug warehouse with very narrow aisle pallet storage and vertical carousels
for small items. Designed to hold as much product as possible in an area where space is
Sample warehouse layout - #2
- Cross dock layout where pre-picked and stretch wrapped pallets from a local supplier of
bulky seasonal items came in the night before, and were then shipped to the chains stores
in their own trucks the next day. Picked pallets of product and cartons received and
sorted directly to outgoing store lanes (another form of cross docking) were all
accumulated in dedicated store lanes for cross dock shipping with little handling or order
picking being required.
Sample warehouse layout - #3
- Giant cosmetics company with a full flow rack pick to light system at the back wall of
the building (so the conveyor did not bisect the building) and with a large pallet
replenishment area behind the rack (and at right angle s to the flow rack and truck doors
for ease of access.) Note the very large packing area after the pick area where picked
cartons (in totes for ease of conveyor handling) came in in one level and the sealed
cartons left on another level directly to the waiting UPS trailers.
Sample warehouse layout - #4
- Seasonal sporting goods and clothing slotted by "sport" as well as
"season" and "year round HUB" areas Picking walk time was minimized
and product did not have to be moved when it was "off" season. Picking was with
batch picking cart.
Sample warehouse layout - #5
- Example of a pallet and broken case ABC pick area sorted by product size and movement.
Broken case picking was done from shelving in the bottom level of the pallet rack with
pallet storage overhead to insure full use of warehouse cube. Small quantity picking was
by case and batch picking with a multi-order picking cart.
Sample warehouse layouts -#6
- Large scale JIT furniture parts warehouse located near the main office furniture
assembly operation. Product families were placed together (by color in the drawing) for
speed of picking. There were truck load deliveries between the buildings every 2 hours or
so over a two shift operation.
Sample warehouse layouts - #7
- Design to integrate two new companies products into an addition to an existing
warehouse. Note use of ABC pick areas for both of the new companies. This layout used
batch picking carts for picking and conveyor to transport small shipments (UPS) from the
existing warehouse section.
Sample of small warehouse
layouts - 3 configurations
could a great new warehouse layout do for YOU?
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Some Recent Testimonials
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you are very welcome for the references. You may not know
this but we RAVE about the suggestions you made to us for
our "Distribution Center", and how right your
suggestions were…" Dan G.,
Pres., Pipersville, PA.
forward to having you involved for our DC implementation plan
and in future endeavors as well. Your input was extremely
valuable to us".
Brent T., President Jacksonville, FL
is incredibly difficult - I would never have been able
to do this without all your great help"! Dave W.,
Owner, Chicago, IL.
I wanted to say that all your suggestions work great! Thanks so much.
Secondly, in the later part of May, we will be moving out of our current
facility into a new one. I was wondering if I gave you the layout could
you draw up a design. You told me if there were ever changes, just ask for
a new layout, so here I am. Thanks a lot!" Bob V., Owner, New Kensington, PA
know it has been a while, but we finally signed on a new
building, and are looking at a mid July move. We have three
dock highs, and two roll ups. Please do your magic and lay out
the floor space. Thanks." Rami R.,
Owner, Chatsworth, CA
renovation is going great. The large shelving is all moved and
the small shelving is about 75% in its new location. A company
is coming in Tuesday to build the new shelving...then we can
start to relocate all the product. Thanks for all the help."
Jeff L., Operations Manager, Victoria, BC, Canada.
received the final report, thanks for the summary of findings
and the recommendations. What was most valuable for us was
the process of getting to the goal and the discussions around
it… Thanks again for your help…Joachim
S., Systems Manager, New York, NY
proud to say that our first day of production in our new
location was March 6. Thank you for your work on our
behalf. Looks like we got off to a fine start in the warehouse
and picking areas. It's always a pleasure hearing from you."
Charlie T., Project Manager, Amityville, NY