EAF Logistics

Designing a layout for a warehouse can be daunting, but it doesn’t have to be. Whether you are building your first warehouse or reconfiguring your existing setup, take the guesswork out of it. Follow these ten (10) easy steps to create your very own efficient warehouse space.

1. Identify the functions that need to occur in your warehouse; plot how much space and what infrastructure (ceiling clearance, exhaust ductwork, utilities) you will need for each.
2.  Establish a flow between your functions. Consider the “life cycle” of the items in your warehouse and how you would want them to travel through the physical space; begin with receiving and end with fulfillment. Attempt to create a fluid path for the items to travel. Walk or visualize the flow of your best-selling products; would they be able to move through your warehouse design quickly and efficiently?
3.  Consider flexibility and mobility. If you have a dynamic warehouse in which functions share or overlap zones, and the size of the zones can vary given the demand, consider worksurfaces, carts, and equipment on wheels. This will give you the most flexibility to establish an efficient flow for the task. Remember to reset your warehouse to “zero” after completing the task. It will ensure you can get up and running quickly when the next job needs to commence.
4.  Think through the utilities you’ll need in the center of your warehouse. The most common demand will be electricity. When installing electricity along the perimeter, consider how you will run power to the workstations away from walls and from where you’ll source the power. You could drop outlets from conduits running along the ceiling, cut into your concrete slab and install outlets in the middle of the floor, or plug an extension cord into a wall outlet and run it along the floor with a rubber duct cord cover. Err on the side of easy and cost-efficient solutions while being safe until you’ve settled on a permanent layout, then consider the investment.
5.  Use your walls to go vertical. If you are concerned about limited floor space, install shelving along your walls. This allows you to elevate your storage and save the open floor for labor. Consider anchoring your shelves to the walls, and remember to check if they are load-bearing.
6.  Are you investing in product moving equipment? Plan for it! If you plan to have shelves, you should have a ladder to access the higher limits. You should have a pallet jack or forklift if you plan to receive and store items on pallets. Ensure your layout accommodates a clear path of travel and storage locations for every piece of equipment.
7.  Consider a central location for tools, such as a tool chest or a tools-only workbench. Require employees to return their tools upon completing a manufacturing order, task, or shift. The act of returning tools to their “homes” can subconsciously encourage employees to maintain order elsewhere throughout operations.
8.  Make a map of your functional layout. Handing off a physical blueprint for someone else to build can aid in double-checking your work. Once built, a map will help daily operations by ensuring team members know the proper locations for tasks and storage. A map can also be helpful when resetting to zero.
9.  Make a habit of resetting your warehouse to “zero.” Zero should be your base layout when everything is stored correctly, work surfaces are clear of nonessential items, and the warehouse is ready for any function. Reset to zero at the end of a task, shift, or workday. If you find a tool or material to not have an apparent storage location in resetting, note this for future layout iterations.
10.  Live with your layout. Not literally; pajamas and fuzzy slippers are not appropriate for the warehouse. Give your warehouse a chance. Perform an honest assessment of its inefficiencies, collect data points, and plan a future layout reconfiguration.

Given enough forethought, warehouse reconfigurations can be successfully implemented with minimal impact on daily operations.