Creating an efficient warehouse layout is crucial for maximising space, improving workflow, and enhancing overall productivity. A well-planned design ensures optimal use of resources, reduces unnecessary movement, and facilitates seamless operations. In this article, we will explore key aspects of warehouse layout design, including racking arrangements and aisle spacing, to help you optimise your space effectively.
The Importance of a Thoughtful Warehouse Layout
When Shelving Depot designs any warehouse layout we do so with client-specific requirements at the forefront. Every operation is unique and it pays to consider business strategy, staff calibre, and product types when considering the best approach for your warehouse. Taking the time and taking advantage of professional advice can help you make future-proofed decisions that will make your business more successful now and in the future.
Key Considerations for Warehouse Layout Design
1. Assess Your Storage Needs
Start by evaluating the type and volume of goods you handle. Consider factors such as:
- Dimensions and weight of items.
- Storage requirements (e.g. temperature-controlled areas).
- Frequency of access for different product categories.
2. Choose the Right Racking System
Selecting the appropriate racking system is essential for efficiency. Popular options include:
- Selective racking: Ideal for warehouses needing easy access to all items. Suitable for diverse inventory.
- Drive-in/drive-through racking: Maximises storage density but is best for uniform items accessed less frequently.
- Pallet flow racking: Uses a gravity flow system for high-volume, first-in, first-out (FIFO) inventory management.
3. Plan Aisle Spacing Strategically
Aisle spacing directly impacts the efficiency and safety of your warehouse. The right width depends on your storage system, equipment, and operational needs. As covered in Storage Racking Solutions for Your Factory, different racking systems influence how much space you’ll need between aisles and what type of equipment is required for access.
- Standard aisles: Allow easy access for forklifts and manual handling, making it simple to retrieve stock. However, they take up more floor space, which reduces overall storage capacity and may limit future expansion. Best suited for Selective Racking when direct access to all pallets is a priority and if you have oversized pallets.
- Narrow aisles: Increase storage density by placing racking closer together, making the most of available floor space. This is ideal for warehouses with a high number of SKUs, but it requires a forklift with a smaller turning circle and skilled operators. It works well with Narrow Aisle Racking, which balances accessibility with higher storage capacity.
- Very narrow aisles: Maximise storage capacity by minimising wasted space between racks. This setup allows you to store significantly more stock within the same warehouse footprint. However, it requires specialised handling equipment, which can be more expensive. This approach is best suited for businesses prioritising maximum storage efficiency.
4. Incorporate Technology
Leverage warehouse management systems (WMS) and automation to streamline operations. For example:
- Barcode scanners and RFID for accurate inventory tracking.
- Automated guided vehicles (AGVs) for transporting goods.
- Real-time analytics to monitor layout efficiency and identify areas for improvement.
5. Ensure Flexibility in Design
Design your warehouse with adaptability in mind to accommodate future growth or changes in inventory. Some pallet racking systems and adjustable shelving can provide the flexibility needed for evolving business needs.
Types of Warehouse Layout Designs
At Shelving Depot we design warehouse layouts using different types of shelving, cantilever racking, and pallet racking systems. Often, using a combination of the different types of storage shelving allows for the optimal warehouse layout. Here are some of the most popular layout designs we’ve used:
| Layout Type | Description | Benefits | Best For |
| U-Shaped Layout | Receiving and shipping areas on the same side, with storage in between. | Streamlines goods flow; reduces handling time. | Small to medium warehouses with high turnover. |
| L-Shaped Layout | Receiving and shipping located at adjacent sides. | Separates inbound and outbound processes; moderate throughput efficiency. | Facilities with distinct receiving/shipping needs. |
| Straight-Through Layout | Receiving at one end and shipping at the opposite end. | Smooth, linear goods flow; reduces cross-traffic. | High-volume warehouses with predictable workflows. |
| Modular/Zone Layout | Divides space into zones for receiving, storage, packing, and shipping. | Flexible and scalable; streamlines operations by activity. | Warehouses with diverse product lines. |
| Island/Circular Layout | Central workspace surrounded by storage in a hub-and-spoke arrangement. | Reduces travel time for frequently accessed items; centralises critical operations. | E-commerce and high pick-rate operations. |
| Custom Hybrid Layout | Combines elements of multiple layouts to fit unique operational needs. | Highly tailored to specific workflows; balances storage and handling. | Specialised or irregular layouts. |
Steps to Optimise Your Warehouse Layout
- Map out your space: Create a detailed floor plan, marking structural features like columns, doors, and loading docks.
- Zone your warehouse: Divide the space into zones for receiving, storage, packing, and shipping to streamline workflow.
- Test and refine: Pilot your layout to identify bottlenecks and make necessary adjustments. Consider how different storage systems will impact capacity, safety, and flow.
- Incorporate safety: Include clear signage, designated pathways, and proper lighting in your design.
Conclusion
Designing an efficient warehouse layout requires careful planning and a thorough understanding of your operational needs. By focusing on racking arrangements, aisle spacing, and technological integration, you can create a layout that boosts productivity, maximises space, and enhances safety. A well-optimised warehouse not only supports current operations but also positions your business for future growth.
Take the time to assess your specific requirements and consult with experts if needed. Investing in a well-designed warehouse layout is a strategic decision that pays off in improved efficiency and profitability.
At Shelving Deopt we have a highly experienced team who have designed efficient warehouse layouts for many customers. If you’d like us to take a look at your warehouse, please get in touch.
