Warehouse &

Inventory
Management
SAQLAIN ABBAS
What is layout/design of the
warehouse?
Warehouse layout refers to both the physical structure of your
warehouse and the many components within it.
Objectives of the Warehouse Design
• Optimization of the warehouse space - efficient operations
that will result in minimum investment for maximum potential
productivity.
• Eliminate processes - that do not add value to the product or
goods.
• Enable stock management - suited to the characteristics of
the warehouse and the products themselves.
• Facilitate access and control of the stored units - Improve
the flow of information on materials and people for
optimization of material and human resources.
• Provide flexibility in case of possible structural changes of a
spatial or organizational nature.
Key Space Considerations
• Accurate measurements – both interior & exterior.
• Deduct measurement of fixed areas such as doors, stairways,
sloping floors, beams, outposts, offices etc.
• Mind the height of your warehouse.
• Main installations in the warehouse: electrical installations,
architectural limitations, ventilation system, environmental
conditions, supplies, safety elements, etc.
• Warehouse areas and the type of r-acking systems for each area
of the warehouse
Warehouse Setup Areas
1- Inbound receiving dock: This area is for receiving products and
pallets from delivery trucks. Incoming products arrive with detailed
documentation and are unloaded from the receiving dock, counted,
and prepared for shelving.
 Common Sizes and Space to
Type of Storage/Shelving Best For: Allow in Your Warehouse
Layout
Pallet rack Midweight to heavyweight 4’ deep x 8’ long per unit
storage needs
Heavy-duty shelving Lightweight to midweight storage 3’ to 4’ deep x 6’ to 8’ long
needs per unit
Light-duty shelving Lightweight storage needs 18” to 2’ deep x 4’ long per
unit
Cantilever rack and Specific storage for oversized Varies by need
specialty shelving items
Bins, boxes, and Loose parts and materials Varies, common allowance
hoppers storage is pallet size: 40” x 48”
Small parts and Storing small items in limited None, usually used on
assembly bins space shelves, carts, and/or
workstations
Warehouse Setup Areas
2- Storage and inventory areas: Warehouse storage needs may
take many forms as per the form (liquid, solid etc. ) including:
• Vertical storage
• Dynamic vs static storage
Material Handling Equipment
Options
Common Sizes to Allow in Warehouse Space
Type of Logistics Equipment Best For:
Planning

Stock carts and pallet Operations that move goods within the Allow around 3’ wide x 5’ long for storage
jacks warehouse

Rolling staircases Operations that store volume stock on Approx. 4’ wide x 8’ long
shelves over 8’ in height

Conveyors Operations that are performing light Varies, 18” by 30” width and lengths of 2’
assembly to 24’ are common

Forklifts Operations that move heavy loads within Approx. 11’–13’ aisle clearance
the warehouse
3- Picking and packing areas: Used to prepare incoming customer
orders, these areas are where the entire order picking process takes
place. When an order is received, the warehouse pickers retrieve the
products and packs them.
Think about your operation by exploring the following warehouse
usage needs:
• Most time consuming area and around which elements
• Employees’ movement needs within the warehouse
• How items will be gathered from various warehouse locations
• What items need to be kept close at hand to complete daily tasks.
Picking Methods
• Discrete Picking – used commonly in small warehouses
• Batch picking – picking similar orders in batches, at once.
• Zone picking – pickers are assigned zones, moved on through conveyer belts
• Wave picking – In larger warehouses, mixed method: batch+zone
Workspace Equipment Options
Common Sizes to Allow in Warehouse
Type of Workspace Equipment Best For:
Space Planning

Multi-use tables and Manufacturing, assembly, picking, and Varies. Common sizes run 3’ deep x
workbenches packing 5’ to 8’ long

Specialty manufacturing Manufacturing and assembly needs Varies. Common sizes run 2’ to 3’
assembly stations deep x 5’ to 8’ long

Dedicated packing stations Daily shipping needs Common size is 3’ deep x 6’ to 8’

long

Pallet packing freight scale Operations shipping truck freight regularly 4’ x 4’, or 4’ deep x 6’ long
station

Dedicated shipping station Operations shipping parcels regularly Varies. Common sizes run 3’ deep x
table 5’ to 8’ long
4- Outbound shipping dock: This area is where the packed orders
are placed onto pallet racks and loaded onto trucks for delivery.
Forklifts are usually used to transport them into trucks.
5- Employee space: Designate ample space for warehouse staff to
take breaks, eat, and rest which are separate from work areas. Also
consider offices for on-site warehouse management teams.
Warehouse Management System
• A warehouse management system gives you a real-time view of your inventory’s
performance and helps you greatly optimize your warehouse.
• In fact, 77% of organizations consider warehouse automation systems
a crucial part of maximizing performance.